U.S. patent application number 12/141325 was filed with the patent office on 2009-01-01 for protective layer setting unit, process cartridge, and image forming apparatus, and method of evaluating protective layer setting unit.
Invention is credited to Kumiko HATAKEYAMA, Tsutomu Hayashi, Toshiyuki Kabata, Masahide Yamashita.
Application Number | 20090003853 12/141325 |
Document ID | / |
Family ID | 40160666 |
Filed Date | 2009-01-01 |
United States Patent
Application |
20090003853 |
Kind Code |
A1 |
HATAKEYAMA; Kumiko ; et
al. |
January 1, 2009 |
PROTECTIVE LAYER SETTING UNIT, PROCESS CARTRIDGE, AND IMAGE FORMING
APPARATUS, AND METHOD OF EVALUATING PROTECTIVE LAYER SETTING
UNIT
Abstract
A protective layer setting unit includes a protective agent, and
an application unit for applying the protective agent on an image
carrying member. An attenuated total reflection (ATR) method is
used for detecting a surface condition of the image carrying member
after applying the protective agent. A peak Pa at a given
wavenumber, attributed to the image carrying member, has a peak
area Sa in an infrared spectrum observed after applying the
protective agent. A peak Pb at a given wavenumber, attributed to
the protective agent, has a peak area Sb in the infrared spectrum
observed after applying the protective agent. A peak area ratio of
Sb/Sa is used for evaluating the protective layer setting unit. The
protective layer setting unit is accepted when the Sb/Sa is set to
a given range after applying the protective agent to the image
carrying member for a given time period.
Inventors: |
HATAKEYAMA; Kumiko;
(Sagamihara city, JP) ; Kabata; Toshiyuki;
(Yokohama city, JP) ; Hayashi; Tsutomu; (Susono
city, JP) ; Yamashita; Masahide; (Tokyo, JP) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Family ID: |
40160666 |
Appl. No.: |
12/141325 |
Filed: |
June 18, 2008 |
Current U.S.
Class: |
399/34 ;
399/98 |
Current CPC
Class: |
G03G 21/0094
20130101 |
Class at
Publication: |
399/34 ;
399/98 |
International
Class: |
G03G 21/00 20060101
G03G021/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 27, 2007 |
JP |
2007-169188 |
Mar 13, 2008 |
JP |
2008-064785 |
Claims
1. A protective layer setting unit for forming a protective layer
on an image carrying member, comprising: a protective agent; and an
application unit configured to apply the protective agent on the
image carrying member, the protective layer setting unit employing
an attenuated total reflection (ATR) infrared absorption spectrum
method to detect a surface condition of the image carrying
member.
2. A method of evaluating a protective layer setting to detect a
surface condition of an image carrying member using an attenuated
total reflection (ATR) prism of germanium (Ge) and an incident
angle of infrared light of 45.degree. as a measurement condition,
wherein an absorbance spectrum obtained by the ATR method is
referred to as infrared (IR) spectrum, the method comprising the
steps of: observing an IR spectrum A as an IR spectrum of a surface
of the image carrying member before applying a protective agent,
observing an IR spectrum B as an IR spectrum of the protective
agent alone, observing an IR spectrum C as an IR spectrum of the
surface of the image carrying member after applying the protective
agent, wherein a peak Pa at a given wavenumber in the IR spectrum A
is not substantially observed in the IR spectrum B, the peak Pa
having a peak area Sa in the IR spectrum C being detected, and a
peak Pb at a given wavenumber in the IR spectrum B is not
substantially observed in the IR spectrum A, the peak Pb having a
peak area Sb in the IR spectrum C being detected; and using a peak
area ratio of Sb/Sa, detected in the IR spectrum C, to evaluate an
application amount of the protective agent to the image carrying
member, which is set by the protective layer setting unit, the
protective layer setting unit being accepted when the Sb/Sa being
set to a first value or more after applying the protective agent to
the image carrying member for a first time period, and when the
Sb/Sa being set to a second value or less after applying the
protective agent to the image carrying member for a second time
period, the first time period is shorter than the second time
period, and the first value is smaller than the second value.
3. The protective layer setting method according to claim 2,
wherein the peak Pa, the peak area Sa, the peak Pb, the peak area
Sb, the first value, the first time period, the second value, and
the second time period are selected from a first set of condition
and a second set of condition, and the protective layer setting
unit is evaluated using any one of the first set of condition and
the second set of condition, the first set of condition includes: a
peak Pa1 at 1770 cm.sup.-1 having a peak area Sa1 as the peak Pa,
and the peak area Sa, a peak Pb1 at 2850 cm.sup.-1 having a peak
area Sb1 as the peak Pb, and the peak area Sb, the first value, the
first time period, the second value, and the second time period are
respectively 0.02, 5 minutes, 0.85, and 150 minutes, an application
amount of the protective agent to the image carrying member being
evaluated using a peak area ratio of Sb1/Sa1, the protective layer
setting unit being accepted when the Sb1/Sa1 being set 0.02 or more
after applying the protective agent to the image carrying member
for 5 minutes, and the Sb1/Sa1 being set to 0.85 or less after
applying the protective agent to the image carrying member for 150
minutes, the second set of condition includes: a peak Pa2 at 3040
cm.sup.-1 having a peak area Sa2 as the peak Pa, and the peak area
Sa, a peak Pb2 at 2920 cm.sup.-1 having a peak area Sb2 as the peak
Pb, and the peak area Sb, the first value, the first time period,
the second value, and the second time period are respectively 6.5,
15 minutes, 38, and 120 minutes, an application amount of the
protective agent to the image carrying member is evaluated using a
peak area ratio of Sb2/Sa2, the protective layer setting unit being
accepted when the Sb2/Sa2 being set to 6.5 or more after applying
the protective agent to the image carrying member for 15 minutes,
and the Sb2/Sa2 being set to 38 or less after applying the
protective agent to the image carrying member for 120 minutes.
4. The protective layer setting unit according to claim 1, wherein
the protective agent has paraffin as a main component.
5. The protective layer setting unit according to claim 4, wherein
the protective agent includes the paraffin for 50 to 95 weight
percent in the protective agent.
6. The protective layer setting unit according to claim 4, wherein
the protective agent having the paraffin as a main component is
shaped in a protective agent bar, the application unit includes: a
brush roller having a metal core and a number of fibers formed on
the metal core by an electrostatic implantation method with a fiber
density of 50,000 to 600,000 fibers per square inch, each of the
fibers having a diameter of from 28 .mu.m to 42 .mu.m, the
protective agent bar being pressed against the fibers to scrape the
protective agent, and the fibers being pressed against the image
carrying member to apply the protective agent to the image carrying
member; and a blade configured being pressed against the image
carrying member to form a uniform layer of the protective agent on
the image carrying member.
7. An image forming apparatus, comprising: an image carrying
member; a charge device configured to charge the image carrying
member; and the protective layer setting unit of claim 1.
8. The image forming apparatus according to claim 7, wherein the
image carrying member is a photoconductor.
9. The image forming apparatus according to claim 7, wherein the
protective layer setting unit is assembled with the image carrying
member as a process cartridge.
10. The image forming apparatus according to claim 9, wherein the
process cartridge further includes the charge device.
11. The image forming apparatus according to claim 7, wherein the
charge device charges the image carrying member by an AC charging
method using a direct current voltage superimposed with an
alternating current voltage.
12. A method of evaluating a protective layer setting unit used for
applying a protective agent on a surface of an image carrying
member using an attenuated total reflection (ATR) infrared (IR)
absorption spectrum method to analyze a condition of the surface of
the image carrying member, wherein an absorbance spectrum obtained
by the ATR method is referred to as infrared (IR) spectrum, an IR
spectrum A is observed as an IR spectrum of the surface of the
image carrying member before applying the protective agent, an IR
spectrum B is observed as an IR spectrum of the protective agent
alone, an IR spectrum C is observed as an IR spectrum of the
surface of the image carrying member after applying the protective
agent, a peak Pa in the IR spectrum A is not substantially observed
in the IR spectrum B, the peak Pa having a peak area Sa in the IR
spectrum C being detected by the ATR method, a peak Pb in the IR
spectrum B is not substantially observed in the IR spectrum A, the
peak Pb having a peak area Sb in the IR spectrum C being detected
by the ATR method, the method comprising: 1) identifying and
computing the peak area Sa of the peak Pa in the IR spectrum C; 2)
identifying and computing the peak area Sb of the peak Pb in the IR
spectrum C; and 3) computing a ratio of "Sb/Sa" as an index for
evaluating an application amount of the protective agent to the
image carrying member.
13. The method according to claim 12, wherein, in the ATR method, a
layer thickness of the protective agent is 0.4% to 85% of a
projection depth of infrared light irradiated to a sample to be
evaluated, the projection depth is a depth that an intensity of the
infrared light irradiated into the sample becomes 1/e of an
intensity of the infrared light on a surface of the sample, and the
"e" is the base of natural logarithms.
14. The method according to claim 13, wherein a projection depth of
the peak Pa is 50% to 170% of a projection depth of the peak
Pb.
15. The method according to claim 12, wherein the protective agent
includes paraffin for 50 weight percent or more, and the peak Pb is
attributed to a methylene group.
16. The method according to claim 12, wherein the protective agent
includes an organic compound having a methylene group, and the peak
Pb is attributed to a methylene group.
17. The method according to claim 12, wherein the surface of the
image carrying member includes an organic compound having a phenyl
group, and the peak Pa is attributed to the phenyl group.
18. The method according to claim 12, wherein the surface of the
image carrying member includes an organic compound having a
carbonate bond, and the peak Pa is attributed to the carbonate
bond.
19. The method according to claim 12, wherein the protective layer
setting unit is evaluated as acceptable when the index "Sb/Sa" is
set to a value smaller than a given threshold value when the
protective agent is applied to the image carrying member for a
given time.
20. The method according to claim 12, wherein the image carrying
member is a photoconductor, mountable to any one of a process
cartridge and an image forming apparatus.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from Japanese Patent
Application Nos. 2007-169188, filed on Jun. 27, 2007, and
2008-064785, filed on Mar. 13, 2008 in the Japan Patent Office, the
entire contents of each of which are hereby incorporated by
reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present disclosure generally relates to a protective
layer setting unit for applying a protective agent to an image
carrying member used in an image forming apparatus employing
electrophotography and a process cartridge having the protective
layer setting unit, and more particularly, to a method of
evaluating a surface condition of a image carrying member coated
with a protective agent not including a metal component.
[0004] 2. Description of the Background Art
[0005] Typically, an image forming apparatus using
electrophotography produces an image by sequentially conducting a
series of processes, such as a charging process, an exposure
process, a developing process, and a transfer process to a
photoconductor such as an OPC (organic photoconductor). After
conducting the transfer process, by-products generated by
discharging during the charging process or toner particles
remaining on the photoconductor are removed by a cleaning process.
Such cleaning process can be conducted by using a cleaning blade,
such as a rubber blade, which has a relatively simple and
inexpensive structure but which cleans well.
[0006] However, such cleaning blade has a short lifetime and itself
reduces the useful life of the photoconductor because the cleaning
blade is pressed against the photoconductor to remove residual
materials remaining on the photoconductor. More specifically,
frictional pressure between the cleaning blade and the
photoconductor abrades the rubber blade and a surface layer of a
photoconductor.
[0007] Further, small-sized toner particles, used for coping with
demand for higher quality images, may not be effectively trapped by
such a cleaning blade, referred to as "passing of toner" or "toner
passing." Such toner passing is more likely to occur by
insufficient dimensional or assembly precision of the cleaning
blade or when the cleaning blade vibrates unfavorably due to an
external shock or the like. If such toner passing occurs, desired
higher quality images may not be produced.
[0008] Accordingly, to extend the lifetime of the photoconductor
and to produce higher quality images over time, frictional pressure
on the photoconductor or cleaning blade needs to be reduced and
cleaning performance of the photoconductor needs to be enhanced, by
which degradation of the photoconductor or cleaning blade can be
reduced and the aforementioned "toner passing" can be reduced.
[0009] Given the need for such frictional pressure reduction and
cleaning performance enhancement, in general, a lubricant is
applied to the photoconductor to form a lubricant layer on the
photoconductor using the cleaning blade. Such lubricant layer can
protect the surface of the photoconductor from an effect of
frictional pressure caused by the cleaning blade pressing against
the photoconductor, which abrades the photoconductor, or from a
discharge energy effect during a charging process, which degrades
the photoconductor. Further, the photoconductor having such
lubricant layer can enhance lubricating performance of the
photoconductor surface, by which an unfavorable vibration of
cleaning blade can be reduced, and thereby toner passing amount can
be reduced.
[0010] Such lubricating and protection performance of the lubricant
is affected by an amount of lubricant applied on the
photoconductor, requiring that an application amount of lubricant
be carefully controlled. If the application amount of lubricant is
too small, the aforementioned photoconductor abrasion by frictional
pressure, photoconductor degradation by charging process, and toner
passing may not be effectively reduced. Accordingly, the state of
the lubricant application on the photoconductor, such as
application amount, needs to be measured.
[0011] In general, a metallic soap such as zinc stearate is used as
the lubricant. However, zinc stearate may adhere to a charge roller
of an image forming apparatus and cause unfavorable charging, which
may result in a lower quality image, for example an image
containing black streaks. When zinc stearate is used as the
lubricant, a lubricant amount of zinc stearate applied to a
photoconductor is analyzed using XPS (X-ray photoelectron
spectroscopy), in which the amount of zinc element as a percentage
of all elements on the surface of the photoconductor is
measured.
[0012] In XPS analysis, elements other than hydrogen existing in a
top and a sub-surface of a sample can be detected. When an OPC
(organic photoconductor) coated with zinc stearate is analyzed
using XPS, an element amount profile detected by XPS varies
depending on a coating amount or coating ratio of zinc stearate.
For example, when no zinc stearate is applied to the OPC, the
element amount profile shows an element distribution of the OPC
itself, whereas when zinc stearate is applied to the OPC, the
element amount profile shows a mixture of the element distribution
of the OPC and the element distribution of the zinc stearate. If
the zinc stearate is applied to the entire surface of the OPC
(i.e., OPC is 100% coated with zinc stearate), the element amount
profile only shows the element distribution of the zinc stearate,
and therefore an upper limit of zinc amount or ratio on the OPC
becomes a zinc amount or ratio of the zinc stearate itself.
Accordingly, when zinc stearate, which has a chemical composition
of C.sub.36H.sub.70O.sub.4Zn, coats the entire surface of the
photoconductor, theoretically the ratio of zinc to all elements
should be 2.44%, which is the ratio of zinc to all the elements in
zinc stearate (C.sub.36H.sub.70O.sub.4Zn) excluding hydrogen.
[0013] However, XPS or X-ray fluorescence (XRF) analysis is
preferably used for detecting metal components. Therefore, when a
protective agent such as paraffin, which does not contain metal, is
applied to the OPC, XPS analysis shows only peak values for carbon
(C) and oxygen (O), meaning that the amount of protective agent
applied to the photoconductor may not be effectively measured.
Inductively coupled plasma (ICP) spectroscopic analysis, which can
be similarly used to evaluate the amount of protective agent
applied to the photoconductor by detecting the metal component in
the protective agent, also suffers from the same drawback and
cannot be used to effectively measure the amount of a protective
agent such as paraffin that does not contain metal.
[0014] Further, an attenuated total reflection (ATR) method is
known for analyzing organic materials. In the ATR method, infrared
absorption spectrum is measured using total reflection.
Specifically, an ATR prism having a higher refractive index is
closely contacted against a sample, an infrared (IR) light is
irradiated to the sample via the ATR prism, and then an outgoing
light from the ATR prism is analyzed spectrometrically. The
infrared light can be totally reflected at a contact face of the
ATR prism and the sample (i.e., total reflection) when the infrared
light is irradiated to the ATR prism with a given angle or more,
wherein such given angle is determined based on a relationship of
the refractive index of the ATR prism and the sample. During such
IR light irradiation, the IR light reflects from an internal
surface of the ATR prism and generates an evanescent wave which
projects orthogonally into the sample. Some of the energy of the
evanescent wave is absorbed by the sample and the reflected IR
light is attenuated and received by a detector, by which absorption
spectrum of the sample can be obtained.
[0015] The ATR method is useful because it can accommodate various
samples because an absorption spectrum of the sample can be
measured by contacting a portion of the sample against the ATR
prism. For example, absorption spectrum of a thick sample or
low-transmittance sample can be measured if such sample can be
closely contacted to the ATR prism. Moreover, in the ATR method, a
functional group in the sample can be determined based on
wavenumber corresponding to absorbed infrared light, and therefore
the ATR method is widely used for qualitative analysis. However,
because a peak intensity of absorption spectrum varies due to the
pressure with which the sample is pressed against the ATR prism,
and therefore the ATR method may not be used so often for
quantitative analysis.
[0016] Recently, a charging process for electrophotography has been
employing AC charging using a charge roller, in which an
alternating current voltage is superimposed on the direct current
voltage. Such AC charging has many advantages, in that it can
charge a photoconductor more uniformly, can reduce generation of
oxidizing gas, such as ozone and nitrogen oxide (NOx), and can
contribute a size reduction of an image forming apparatus, for
example.
[0017] However, a photoconductor may be acceleratingly degraded
because a discharge of positive and negative voltages repeatedly
occurs with a frequency of the applied alternating current voltage,
such as several hundred to several thousand times per second
between a charging device and the photoconductor. Such degradation
of the photoconductor can be reduced by applying a lubricant, such
as metallic soap, on the photoconductor because such lubricant can
absorb discharge energy of the AC charging so as to prevent the
discharge energy effect to the photoconductor.
[0018] Such lubricant (e.g., metallic soap) itself also may be
decomposed by the AC charging. More precisely, the metallic soap is
not decomposed completely but to a lower molecular weight fatty
acid, and a friction pressure between the photoconductor and a
cleaning blade increase as the lubricant is decomposed. Such fatty
acid and toner may adhere to the photoconductor as a film which
degrades image resolution, abrades the photoconductor, and causes
uneven image concentration.
[0019] In light of such phenomenon, a greater amount of metallic
soap may be applied on the photoconductor so as to effectively coat
a surface of the photoconductor with metallic soap even if some
fatty acid may be generated. However, in actuality only some of the
metallic soap may actually adhere to the photoconductor even if the
photoconductor is supplied with a greater amount of metallic soap,
and most of the metallic soap applied on the photoconductor may be
transferred with toner, or removed with waste toner, for example.
Accordingly, the metallic soap may be consumed rapidly, and the
metallic soap may need to be replaced with new metallic soap in a
time period, which may be shorter than a lifetime of the
photoconductor.
[0020] In view of such drawback, instead of using metallic soap,
higher alcohol having a greater carbon number, such as from 20 to
70, is used as a main component of a lubricant (or protective
agent) in one related art. When such lubricant is applied to a
photoconductor, higher alcohol accumulates on a leading edge of a
cleaning blade as indefinite-shaped particles, and such lubricant
has surface wet-ability with the surface of photoconductor, by
which such lubricant can be used for a long period of time.
[0021] However, if higher alcohol is used as lubricant, one
molecule of higher alcohol may coat a relatively larger area on the
photoconductor, and thereby density of higher alcohol molecules
absorbed on the photoconductor per unit area may become smaller
(i.e., smaller molecular weight per unit area), which is not
preferable from a viewpoint of reducing the electrical stress of
the AC charging to the photoconductor.
[0022] Another related art proposes using powder of an alkylene
bis-alkyl acid amide compound as a lubrication component to supply
powder to a surface boundary between a photoconductor (or image
carrying member) and a cleaning blade, contacting the
photoconductor, so as to provide smooth lubrication effect on the
surface of the photoconductor for a long period. However, if the
lubricant having nitrogen atom is used, the lubricant itself may
generate decomposition products having ion-dissociative property,
such as nitrogen oxide and a compound having ammonium when the
lubricant is subjected to the electrical stress of AC charging.
Such products then intrude into a lubrication layer, reducing
resistance of the lubrication layer under a high-humidity condition
and possibly causing grainy images as a result.
[0023] It is known that a protective agent having paraffin as a
main component can protect a photoconductor from the electrical
stress of AC charging, can reduce a frictional pressure between the
photoconductor and a cleaning blade, and can remove toner remaining
on the photoconductor well, for example. Further, the protective
agent having paraffin may not generate so much fatty acid even if
the protective agent is oxidized by the electrical stress of AC
charging, which is preferable for reducing a variation of the
frictional pressure between the photoconductor and the cleaning
blade. However, when image forming operations are repeated by using
the protective agent having paraffin, abnormal images, such as
streak image, are produced in some cases, wherein such abnormal
images may be caused by abrasion of the photoconductor and the
cleaning blade. Based on research, probability of such abnormal
images varies among product lots of protective layer setting units.
Research was further conducted for photoconductors, which produced
and did not produce abnormal images, to find that the abnormal
images occurred on an area where a layer thickness of the
photoconductor was relatively thinner or an area where toner was
attracted with a greater amount on the photoconductor. However,
root causes of such abnormal images are known yet.
[0024] As mentioned, paraffin can be effectively used as a
protective agent instead of metallic soap. However, when a
protective agent, such as paraffin, not containing metal component
is applied to the OPC, XPS or XRF analysis show only peak values
for carbon (C) and oxygen (O), and therefore the amount of
protective agent applied to the photoconductor may not be
effectively evaluated. Further, ICP spectroscopic analysis may not
be suitable for effectively evaluating the amount of protective
agent, not containing metal component, applied to the
photoconductor because the ICP spectroscopic analysis is also used
for detecting a protective agent (e.g., metallic soap) having metal
component. If the amount of protective agent on a photoconductor
cannot be effectively evaluated, a photoconductor having an
insufficient amount of protective agent may be assembled in a
process cartridge or an image forming apparatus, and such
photoconductor can cause image quality degradation.
[0025] As such, a conventional analysis method may not be suitable
for detecting an amount of a protective agent, such as paraffin,
not including a metal component, and therefore a method of
effectively evaluating a surface condition of a photoconductor
coated with a protective agent not including a metal component is
desired.
SUMMARY
[0026] In an aspect of the present disclosure, a protective layer
setting unit for forming a protective layer on an image carrying
member includes a protective agent, and an application unit for
applying the protective agent on the image carrying member. The
protective layer setting unit employs an attenuated total
reflection (ATR) infrared absorption spectrum method to detect a
surface condition of the image carrying member.
[0027] In another aspect of the present disclosure, a method of
evaluating a protective layer setting is devised to detect a
surface condition of an image carrying member using an attenuated
total reflection (ATR) prism of germanium (Ge) and an incident
angle of infrared light of 45.degree. as a measurement condition.
An absorbance spectrum obtained by an ATR method is referred to as
infrared (IR) spectrum. The method includes: observing an IR
spectrum A as an IR spectrum of a surface of the image carrying
member before applying a protective agent, observing an IR spectrum
B as an IR spectrum of the protective agent alone; observing an IR
spectrum C as an IR spectrum of the surface of the image carrying
member after applying the protective agent, in which a peak Pa at a
given wavenumber in the IR spectrum A is not substantially observed
in the IR spectrum B, and the peak Pa has a peak area Sa in the IR
spectrum C, whereas a peak Pb at a given wavenumber in the IR
spectrum B is not substantially observed in the IR spectrum A, and
the peak Pb has a peak area Sb in the IR spectrum C; and using a
peak area ratio of Sb/Sa. The peak area ratio of Sb/Sa, detected in
the IR spectrum C, is used to evaluate an application amount of the
protective agent to the image carrying member, which is set by the
protective layer setting unit. The protective layer setting unit is
accepted when the Sb/Sa is set to a first value or more after
applying the protective agent to the image carrying member for a
first time period, and when the Sb/Sa is set to a second value or
less after applying the protective agent to the image carrying
member for a second time period. The first time period is shorter
than the second time period, and the first value is smaller than
the second value.
[0028] In another aspect of the present disclosure, a method of
evaluating a protective layer setting unit used for applying a
protective agent on a surface of an image carrying member using an
attenuated total reflection (ATR) infrared (IR) absorption spectrum
method is devised to analyze a condition of the surface of the
image carrying member. An absorbance spectrum obtained by the ATR
method is referred to as infrared (IR) spectrum. An IR spectrum A
is observed as an IR spectrum of the surface of the image carrying
member before applying the protective agent, an IR spectrum B is
observed as an IR spectrum of the protective agent alone, and an IR
spectrum C is observed as an IR spectrum of the surface of the
image carrying member after applying the protective agent. A peak
Pa in the IR spectrum A is not substantially observed in the IR
spectrum B, and the peak Pa has a peak area Sa in the IR spectrum C
detected by the ATR method. A peak Pb in the IR spectrum B is not
substantially observed in the IR spectrum A, and the peak Pb has a
peak area Sb in the IR spectrum C detected by the ATR method. The
method includes 1) identifying and computing the peak area Sa of
the peak Pa in the IR spectrum C; 2) identifying and computing the
peak area Sb of the peak Pb in the IR spectrum C; and 3) computing
a ratio of "Sb/Sa" as an index for evaluating an application amount
of the protective agent to the image carrying member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] A more complete appreciation of the disclosure and many of
the attendant advantages and features thereof can be readily
obtained and understood from the following detailed description
with reference to the accompanying drawings, wherein:
[0030] FIG. 1 shows one pattern of IR spectrum A to C used for
detection;
[0031] FIG. 2 shows one pattern of IR spectrum peaks, which is not
preferable for detection;
[0032] FIG. 3 shows another one pattern of IR spectrum A to C used
for detection;
[0033] FIG. 4 shows another pattern of IR spectrum A to C used for
detection;
[0034] FIG. 5 shows one pattern of IR spectrum, which is not
preferable for detection;
[0035] FIG. 6 shows another one pattern of IR spectrum A to C used
for detection;
[0036] FIG. 7 illustrates a schematic configuration of a protective
layer setting unit used for evaluation;
[0037] FIG. 8 shows example IR spectrum, in which IR spectrum A is
for a photoconductor surface before applying the protective agent,
IR spectrum B is for a protective agent alone, IR spectrum C is for
a photoconductor surface after applying a protective agent, and
differential spectrum D, obtained by subtracting IR spectrum A from
the IR spectrum C;
[0038] FIG. 9 illustrates a schematic configuration of a protective
layer setting unit according to an exemplary embodiment, which is
used in an image forming engine;
[0039] FIG. 10 illustrates a schematic cross-sectional view of a
process cartridge having a protective layer setting unit according
to an exemplary embodiment;
[0040] FIG. 11 illustrates a schematic cross-sectional view of an
image forming apparatus having a protective layer setting unit
according to an exemplary embodiment;
[0041] FIG. 12 illustrates an image pattern used for evaluating a
process cartridge according to exemplary embodiments;
[0042] FIG. 13 shows conditions of peak used for computing a peak
area for each of peaks, in which start and end point of background
for computing a peak area, and integration area of peak are
included with wavenumber information;
[0043] FIGS. 14 to 17 show conditions for protective agent bars,
protective layer setting units, ATR analysis, and results of ATR
analysis and image evaluation for Example;
[0044] FIG. 18 shows conditions of peak used for computing a peak
area for each of peaks, in which start and end point of background
for computing a peak area, and integration area of peak are
included with wavenumber information;
[0045] FIGS. 19 to 22 show conditions for protective agent bars,
protective layer setting units, ATR analysis, and results of ATR
analysis and image evaluation for Example and Comparative
Example;
[0046] FIG. 23 shows conditions of peak used for computing a peak
area for each of peaks, in which start and end point of background
for computing a peak area, and integration area of peak are
included with wavenumber information; and
[0047] FIGS. 24 to 27 show conditions for protective agent bars,
protective layer setting units, ATR analysis, and results of ATR
analysis and image evaluation for Example and Comparative
Example.
[0048] The accompanying drawings are intended to depict exemplary
embodiments of the present invention and should not be interpreted
to limit the scope thereof. The accompanying drawings are not to be
considered as drawn to scale unless explicitly noted, and identical
or similar reference numerals designate identical or similar
components throughout the several views.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0049] A description is now given of exemplary embodiments of the
present invention. It should be noted that although such terms as
first, second, etc. may be used herein to describe various
elements, components, regions, layers and/or sections, it should be
understood that such elements, components, regions, layers and/or
sections are not limited thereby because such terms are relative,
that is, used only to distinguish one element, component, region,
layer or section from another region, layer or section. Thus, for
example, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the present invention.
[0050] In addition, it should be noted that the terminology used
herein is for the purpose of describing particular embodiments only
and is not intended to be limiting of the present invention. Thus,
for example, as used herein, the singular forms "a", "an" and "the"
are intended to include the plural forms as well, unless the
context clearly indicates otherwise. Moreover, the terms "includes"
and/or "including", when used in this specification, specify the
presence of stated features, integers, steps, operations, elements,
and/or components, but do not preclude the presence or addition of
one or more other features, integers, steps, operations, elements,
components, and/or groups thereof.
[0051] Furthermore, although in describing expanded views shown in
the drawings, specific terminology is employed for the sake of
clarity, the present disclosure is not limited to the specific
terminology so selected and it is to be understood that each
specific element includes all technical equivalents that operate in
a similar manner.
[0052] A description is now given to a method of evaluating a
protective layer setting unit according to an exemplary embodiment.
In an exemplary embodiment, an attenuated total reflection method
(hereinafter, referred as ATR method or ATR) is used to evaluate a
protective agent not including a metal component, such as paraffin,
applied to a photoconductor. In the ATR method, a projection depth
of infrared (IR) light into a sample becomes different depending on
measurement conditions, such as ATR prism, incident angle, by which
results of measured spectrum of a same sample may become different
depending on such measurement conditions. For example, one spectrum
result shows only a peak attributed to a photoconductor, another
spectrum result shows only a peak attributed to a protective agent,
or another spectrum result shows a mixture of a peak attributed to
a photoconductor and a peak attributed to a protective agent.
[0053] In an exemplary embodiment, measurement condition which can
detect both of a peak attributed to a photoconductor and a peak
attributed to a protective agent is determined based on researches
on measurement conditions, in which a plurality of conditions were
examined for ATR prism, incident angle, or the like. Under such
measurement condition, an infrared (IR) spectrum profile for a
photoconductor is measured to evaluate an application amount of the
protective agent applied on the photoconductor.
[0054] In the ATR method, a spectrum profile of a sample may vary
for each of measurements because a measurement portion of a sample
deforms by a pressure for holding the sample, wherein such pressure
may vary for each of the measurements although such pressure may be
controlled within a given range. Accordingly, a peak intensity of
target component, which is used for detecting a surface condition
of the sample, may vary for each of measurements. Accordingly, peak
intensity of spectrum alone may not be used for effectively
detecting a surface condition of the sample.
[0055] In view of such peak intensity variation of one sample, a
substantially consistent condition may be set when setting a sample
on a measurement device so as to obtain infrared (IR) spectrum
profile under a constant condition. Specifically, a gap between a
fixing jig for holding the sample and the ATR prism is maintained
at a substantially consistent level, or a pressure for holding the
sample is maintained at a substantially consistent level. Under
such condition, a measurement of infrared (IR) spectrum profile is
conducted for a photoconductor applied with the protective agent,
and each peak in the IR spectrum profile is evaluated and
attributed to a specific material, functional group, or the like
while changing an application time of the protective agent for each
of sample photoconductors. In an exemplary embodiment, a peak area
ratio between a peak area attributed to a photoconductor and a peak
area attributed to a protective agent is computed, in which the
peak area ratio becomes greater as an application time of the
protective agent increases.
[0056] In an exemplary embodiment, an application amount of the
protective agent applied to a surface of a photoconductor is
evaluated as follows. In this disclosure, a protective layer
setting unit is used to apply the protective agent to the surface
of photoconductor (in this disclosure, surface of photoconductor
may be referred as photoconductor surface).
[0057] Specifically, an IR spectrum A of the photoconductor surface
before applying the protective agent and an IR spectrum B of the
protective agent alone are measured by the ATR method using
infrared absorption spectrum. The IR spectrum A has at least one
absorption peak that is not substantially included in the IR
spectrum B, and the IR spectrum B has at least one absorption peak
that is not substantially included in the IR spectrum A, for
example, wherein the number of such absorption peak may be one or
more. After applying the protective agent using the protective
layer setting unit, an IR spectrum C of the photoconductor is
observed. Specifically, the IR spectrum A has a given specific peak
that is not substantially included in the IR spectrum B, which is
termed as a peak Pa and such peak Pa has a peak area Sa in this
disclosure. The IR spectrum B has a given specific peak that is not
substantially included in the IR spectrum A, which is termed as a
peak Pb and such peak Pb has a peak area Sb in this disclosure. The
application amount of the protective agent on the photoconductor is
evaluated using a peak area ratio "Sb/Sa" for such peaks Pa and Pb,
which is observed in the IR spectrum C, obtained after applying the
protective agent on the photoconductor.
[0058] A description is given to a relative position of peaks in
the IR spectrum A, the IR spectrum B, and the IR spectrum C with
reference to FIGS. 1 to 3. As aforementioned, the IR spectrum C is
a spectrum after applying the protective agent on the
photoconductor, and thereby the IR spectrum C includes peaks
attributed to both of the IR spectrum A and B.
[0059] In FIG. 1, the peak Pa of the IR spectrum A has a
wavenumber, which is not substantially detected in the IR spectrum
B. In other words, a peak is not substantially detected in the IR
spectrum B at the wavenumber that the peak Pa is detected in the IR
spectrum A. If a peak is detected in both of the IR spectrum A and
B at a same wavenumber as shown in FIG. 2, such peak (peak M in
FIG. 2) is not preferably used for computing the peak area ratio
"Sb/Sa." Preferably, as shown in FIG. 3, the peak Pa in the IR
spectrum A and a given specific peak (peak K) in the IR spectrum B
have no overlapping area. In other words, it is preferable that the
peak Pa and the peak K do not overlap each other at peak top or
tail of each peak.
[0060] If the peak Pa and the peak K overlap each other at peak top
or tail of each peak as shown in FIG. 1, a differential spectrum of
the IR spectrum C and the IR spectrum B needs to be computed, in
which a peak area of the peak K is subtracted from the IR spectrum
C to obtain a correct value of the peak Pa, by which the peak area
ratio "Sb/Sa" can be computed effectively by eliminating an effect
of the peak K of the IR spectrum B.
[0061] However, such subtraction step can be omitted if the peak Pa
has a too great area compared to the peak K even if the peak Pa and
the peak K overlap each other at peak top or tail of each peak. If
such subtraction step can be omitted, a computation of the peak
area ratio "Sb/Sa" can be simplified and a computation can be
conducted more precisely.
[0062] In FIG. 4, the peak Pb of the IR spectrum B has a
wavenumber, which is not substantially detected in the IR spectrum
A. In other words, a peak is not substantially detected in the IR
spectrum A at the wavenumber that the peak Pb is detected in the IR
spectrum B. If a peak is detected in both of the IR spectrum A and
the IR spectrum B at a same wavenumber as shown in FIG. 5, such
peak (peak N in FIG. 5) is not preferably used for computing the
peak area ratio "Sb/Sa."
[0063] Preferably, as shown in FIG. 6, the peak Pb in the IR
spectrum B and a given specific peak (peak L) in the IR spectrum A
have no overlapping area. In other words, it is preferable that the
peak Pb and the peak L do not overlap each other at peak top or
tail of each peak. If the peak Pb and the peak L overlap each other
at peak top or tail of each peak as shown in FIG. 4, a differential
spectrum of the IR spectrum C and the IR spectrum A needs to be
computed, in which a peak area of the peak L is subtracted from the
IR spectrum C to obtain a correct value of the peak Pb, by which
the peak area ratio "Sb/Sa" can be computed effectively by
eliminating an effect of the peak L of the IR spectrum A.
[0064] However, such subtraction step can be omitted if the peak Pb
has a too great area compared to the peak L, even if the peak Pb
and the peak L overlap each other at peak top or tail of each peak
as shown in FIG. 4. If such subtraction step can be omitted, a
computation of the peak area ratio "Sb/Sa" can be simplified and a
computation can be conducted more precisely.
[0065] IR spectrum indicates a change of intensity profile of a
sample with respect to a wavenumber (or wavelength) of an infrared
light source. Such IR spectrum profile is drawn as a curve profile
by setting wavenumber (cm.sup.-1), which is an inverse number of
wavelength, in a horizontal axis and setting transmission factor
(T) or absorbance (a) in a vertical axis. The transmission factor
(T) is a ratio of light energy entered a sample and light energy
transmitted from the sample, and the absorbance (a) is obtained by
a process of common logarithm of an inverse number of the
transmission factor (T). Because the absorbance is proportional to
sample concentration (Lambert-Beer law), peak intensity of
absorbance spectrum is used for quantitative determination of
sample. As for a peak intensity of IR spectrum, absorbance is
preferably used for quantitative analysis instead of the
transmission factor.
[0066] In general, IR spectrum can be measured by two types of
machine: diffusion type infrared spectrophotometer and fourier
transform infrared spectrophotometer, wherein the fourier transform
infrared (FT-IR) spectrophotometer is mainly used for IR spectrum
measurement in view of higher efficiency on measurement time, light
energy usage, resolution power of wavenumber, and precision of
wavenumber. IR spectrum can be measured with such machine using
methods, such as a transmission method or the like, which can be
selected depending on a purpose of measurement, sample shape, or
the like. Among the measurement methods, the ATR method is widely
used for FT-IR measurement because the ATR method does not need a
complex sample treatment for IR spectrum measurement.
[0067] In the ATR method, a sample is contacted to an ATR prism for
measurement. Accordingly, a deviation of contact condition of the
sample and ATR prism may affect measurement of peak intensity.
Specifically, even if a same sample is measured, measurement
results may deviate among each of measurements, which is not
preferable for quantitative analysis. Recently, several accessories
have been devised to control such contact condition. For example,
one accessory is used to maintain a gap between an ATR prism and a
holding jig, which fixes a sample, at a given level; another
accessory is used to maintain a pressure applied to a sample at a
given level; and another accessory having a pressure gauge, which
can change pressure applied to a sample, is used.
[0068] Such accessories can reduce deviation of measurement results
for peak intensity. However, when one accessory for maintaining a
gap between an ATR prism and a holding jig is used and the gap is
measured for several times using a same sample, a variation of
about 20% may be observed for the gap. Because of such variation of
gap distance, it is hard to effectively evaluate an application
amount of the protective agent on the photoconductor by just using
peak intensity alone. Instead, an peak area ratio between a peak
area attributed to a protective agent and a peak area attributed to
a photoconductor is used for evaluating an application amount of
the protective agent to the photoconductor, to conduct an
evaluation of an application amount of the protective agent more
reliably. Such peak area ratio may be used as an evaluation
index.
[0069] In an exemplary embodiment, a layer thickness of protective
agent is 0.4% to 85% of a projection depth of infrared light used
in the ATR method using infrared absorption spectrum. In the ATR
method, infrared light is not reflected on a boundary face of a
sample and an ATR prism, but infrared light projects into an
internal portion of a sample (or projects for a projection depth in
a sample) and then reflects as total reflection from the projection
depth. The projection depth of infrared light is a distance from a
surface of a sample, wherein an infrared light intensity at such
distance becomes "1/e" of an infrared light intensity on the
surface of the sample, which is defined by the following equation
1, in which "e" is the base of natural logarithms.
[0070] As indicated in the equation 1, the projection depth of
infrared light to the sample is determined by incident angle,
refractive index of ATR prism, and wavelength of light.
Specifically, the greater the incident angle .theta., the greater
the refractive index of ATR prism, or the smaller the measurement
wavelength, the projection depth becomes smaller. If a smaller
projection depth is used, a condition closer to the surface of the
sample can be obtained as IR spectrum.
dp=.lamda./2.pi.n.sub.1[sin.sup.2.theta.-(n.sub.2/n.sub.1).sup.2].sup.1/-
2 (equation 1) [0071] dp: projection depth [0072] n.sub.2 and
n.sub.1: refractive index of ATR prism and sample [0073] .theta.:
incident angle [0074] .lamda.: wavelength
[0075] Depending on a layer thickness of protective agent, ATR
prism, incident angle of infrared light, and wavelength for an
index peak are selected, wherein the index peak is the peak Pa and
peak Pb. Such ATR prism, incident angle of infrared light, and
wavelength for an index peak are selected so as to set the layer
thickness of protective agent as 0.4% to 85% of the projection
depth of infrared light, preferably 15% to 70%, and more preferably
25 to 60%.
[0076] If the layer thickness of protective agent is too great
compared to the projection depth of infrared light, the peak area
Sb for the peak Pb is saturated at a given level, and a peak
intensity for the peak Pa becomes smaller, by which the peak area
Sa for the peak Pa has a greater error, and the peak area ratio
"Sb/Sa" is affected by the error of peak area Sa, which is not
preferable.
[0077] If the layer thickness of protective agent is too small
compared to the projection depth of infrared light, the peak area
Sa for the peak Pa is saturated at a given level, and a peak
intensity for the peak Pb becomes too small, by which the peak area
Sb for the peak Pb has a greater error, and the peak area ratio
"Sb/Sa" is affected by the error of peak area Sb, which is not
preferable.
[0078] If the layer thickness of protective agent is not within a
range of the 0.4 to 85% of the projection depth when a
photoconductor supplied with a protective agent is measured by the
ATR method under a condition having a specific ATR prism, a
specific incident angle of infrared light, and a specific
wavelength for index peak, the projection depth can be changed to
preferable value by adjusting refractive index of ATR prism,
incident angle of infrared light, and wavelength of index peak as
indicated in the equation 1. Accordingly, if the projection depth
is too small or too great with respect to the thickness of
protective agent, refractive index of ATR prism, incident angle of
infrared light, and wavelength of index peak used for computing an
application amount of protective agent may need to be adjusted so
as to set a preferable relationship between a layer thickness of
the protective agent and projection depth.
[0079] In some cases, the projection depth may not be adjusted by
adjusting wavelength of index peak because the wavelength of index
peak is dependent to material types of protective agent and
photoconductor when a specific ATR prism and incident angle of
infrared light are used for the ATR method.
[0080] If the protective agent and photoconductor have a plurality
of functional groups and each of the functional group has a peak,
which can be detected at a greatly different wavelength, for
example, the projection depth can be adjusted by selecting one peak
for one functional group. For example, a peak having a greater
wavelength is selected to set a greater depth for the projection
depth.
[0081] However, if the protective agent, such as paraffin, has too
little functional group, and only one or several peaks are detected
and if such several peaks are detected at a relatively similar
wavelength, the projection depth cannot be adjusted by selecting
one peak. In this case, the projection depth can be adjusted to a
preferable level by changing the refractive index of ATR prism, and
the incident angle of infrared light.
[0082] In general, the ATR prism may be KRS-5 (refractive index
2.4), germanium (refractive index 4.0), AMTIR (refractive index
2.5), silicon (refractive index 3.4), zinc selenide (refractive
index 2.4), and diamond (refractive index 2.4), or the like. In
general, the incident angle of infrared light for ATR measurement
may be from 30.degree. to 85.degree..
[0083] In an exemplary embodiment, the projection depth of the peak
Pa is from 50% to 170% of the projection depth of the peak Pb,
preferably from 70% to 140%, and more preferably from 80% to 120%.
If the projection depth of the peak Pa becomes too small with
respect to the projection depth of the peak Pb, sensitivity of
evaluation index "Sb/Sa" for determining an application amount of
the protective agent becomes unpreferably small. If the projection
depth of the peak Pa becomes too great with respect to the
projection depth of the peak Pb, sensitivity of evaluation index
"Sb/Sa" for determining an application amount of the protective
agent becomes also unpreferably small.
[0084] In an exemplary embodiment, a protective agent includes
paraffin for 50 wt % (weight percent) or more, for example, and the
peak Pb used for computing evaluation index "Sb/Sa" for determining
an application amount of the protective agent is preferably
attributed to methylene group. Such paraffin includes normal
paraffin, isoparaffin, and cyclo paraffin, for example, which may
be a chemically stable material such as less-likely-to-occur
addition reaction and less-likely-to-occur oxidation reaction in
the atmosphere. Accordingly, paraffin, effectively protecting a
photoconductor, can be preferably used as a protective agent from a
viewpoint of material stability over time.
[0085] In an exemplary embodiment, a protective agent includes
paraffin for 50 wt % (weight percent) or more, preferably 60 wt %
or more, and more preferably 70 wt % or more, for example. If the
paraffin amount included in the protective agent is too small, the
protective agent may not effectively protect a photoconductor,
which is not preferable. However, if a protective agent includes
another component other than paraffin, which has a sufficient
protection effect, the paraffin amount included in the protective
agent can be set less than 50 wt %.
[0086] Further, if the protective agent includes paraffin for 50
weight percent (wt %) or more, methylene peak having a sufficient
peak intensity can be detected at wavenumebrs of 2850.+-.15
cm.sup.-1 and 2925.+-.15 cm.sup.-1, and thereby the peak Pb can be
set as methylene peak corresponding to methylene group in the
protective agent. With such setting for the peak Pb, the evaluation
index "Sb/Sa" for evaluating an application amount of the
protective agent can be computed more reliably. Especially, when a
protective agent, such as paraffin, not including a metal component
and not having too many infrared (IR) peaks that are
distinguishable, an application amount of the protective agent may
not be evaluated effectively except the FT-IR analysis. In view of
such situation, a method according to an exemplary embodiment,
which effectively evaluates a surface condition of a photoconductor
coated with a protective agent not including a metal component, is
desirably used.
[0087] Other than paraffin, a protective agent may include cyclic
olefin copolymer (COC), and amphiphilic organic compound, for
example. Such amphiphilic organic compound may be anionic
surfactant, cationic surfactant, zwitterionic surfactant, nonionic
surfactant, or a complex compound of these, for example.
[0088] The nonionic surfactant may preferably be an ester compound
of alkylcarboxylic acid (see chemical formula (1)) and polyalcohol,
in which "n" is an integral number from 15 to 35.
C.sub.nH.sub.2n+1COOH (chemical formula(1))
[0089] If a straight chain alkylcarboxylic acid is used as
alkylcarboxylic acid (chemical formula(1)), amphiphilic organic
compound can be preferably adhered on a surface of an image
carrying member such as photoconductor. Specifically,
hydrophobicity portion of the amphiphilic organic compound can be
oriented to a surface of an image carrying member in an orderly
manner, and thereby the amphiphilic organic compound can be
preferably adsorbed on the image carrying with a higher adsorption
density.
[0090] Alkylcarboxylic acid ester has hydrophobicity. The greater
the number of alkylcarboxylic acid ester in one molecule, the more
effective to reduce an adsorption of dissociated material generated
by aerial discharge to a surface of an image carrying member such
as photoconductor, and the more effective to reduce a electrical
stress to a surface of the image carrying member during a charging
process. However, if a ratio of alkylcarboxylic acid ester becomes
too great, polyalcohol having hydrophilicity may be blocked by the
alkylcarboxylic acid ester, by which an adsorption performance may
not be effectively obtained depending on a surface condition of an
image carrying member. Accordingly, the average number of ester
bond in one molecule of amphiphilic organic compound may be
preferably from 1 to 3.
[0091] Such average number of ester bond in one molecule of
amphiphilic organic compound can be set or adjusted by selecting
one amphiphilic organic compound or by mixing a plurality of
amphiphilic organic compounds, each compound having different
number of ester bonds. Such amphiphilic organic compound may
include anionic surfactant, cationic surfactant, zwitterionic
surfactant, and nonionic surfactant, as above described.
[0092] Examples of the anionic surfactant include compounds of
alkali metal ion (e.g., sodium, potassium), alkaline-earth metal
ion (e.g., magnesium, calcium), metal ion (e.g., aluminum, zinc),
or ammonium ion bonded with a compound having an anion at
hydrophobicity portion, such as alkyl benzene sulfonate,
.alpha.-olefin sulfonate, alkane sulfonate, sulfuric alkyl salt,
sulfuric alkylpolyoxyethylene salt, alkyl phosphate salt,
long-chain aliphatic acid salt, .alpha.-sulfoaliphatic acid ester
salt, and alkyl ether sulfate.
[0093] Examples of the cationic surfactant include compounds
composed of chlorine, fluorine, bromine, phosphoric ion, nitrate
ion, sulphuric ion, thiosulphuric ion, carbonate ion, and hydroxide
ion, which are bonded to a compound having a cation at
hydrophobicity portion, such as alkyltrimethyl ammonium salt,
dialkylmethyl ammonium salt, and alkyldimethylbenzyl ammonium
salt.
[0094] Examples of the zwitterionic surfactant include
dimethylalkylamine oxide, N-alkylbetaine, imidazoline derivatives,
and alkylamino acid.
[0095] Examples of the nonionic surfactant include alcohol
compound, ether compound, or amide compound, such as long-chain
alkylalcohol, alkylpolyoxyethylene ether, polyoxyethylene alkyl
phenyl ether, aliphatic acid diethanolamide, alkyl polyglucoxide,
and polyoxyethylene sorbitan alkylester. Further, examples of the
nonionic surfactant preferably include long-chain alkylcarboxylic
acid, such as lauric acid, paltimic acid, stearic acid, behenic
acid, lignoceric acid, cerinic acid, montanic acid, melissic acid;
polyalcohol, such as ethylene glycol, propylene glycol, glycerin,
erythritol, hexitol; and ester compound having partially anhydride
compound of these.
[0096] Examples of ester compounds include alkylcarboxylic acid
glyceryl or its substitution, such as monoglyceryl stearate,
diglyceryl stearate, monoglyceryl palmitate, diglyceryl laurate,
triglyceryl laurate, diglyceryl palmitate, triglyceryl palmitate,
diglyceryl myristate, triglyceryl myristate, glyceryl
palmitate/stearate, monoglyceryl arachidate, diglyceryl arachidate,
monoglyceryl behenate, glyceryl stearate/behenate, glyceryl
cerinate/stearate, monoglyceryl montanate, monoglyceryl melissate;
and alkylcarboxylic acid sorbitan or its substitution, such as
monosorbitan stearate, trisorbitan stearate, monosorbitan
palmitate, disorbitan palmitate, trisorbitan palmitate, disorbitan
myristate, trisorbitan myristate, sorbitan paltimate/stearate,
monosorbitan arachidate, disorbitan arachidate, monosorbitan
behenate, sorbitan stearate/behenate, sorbitan cerinate/stearate,
monosorbitan montanate, monosorbitan melissate, but not limited
those. These amphiphilic organic compound can be used alone or in
combinaton.
[0097] In an exemplary embodiment, a protective agent preferably
includes an organic compound having methylene group, and the peak
Pb is preferably attributed to the methylene group for computing
the evaluation index "Sb/Sa" for determining an application amount
of the protective agent. When a protective agent, such as paraffin,
not including a metal component and not having too many infrared
(IR) peaks that are distinguishable, an application amount of the
protective agent may not be evaluated effectively except the FT-IR
analysis. In view of such situation, a method according to an
exemplary embodiment, which effectively evaluates a surface
condition of a photoconductor coated with a protective agent not
including a metal component, is desirably used. Such method can be
used other protective agent having an organic compound having
methylene group, wherein such organic compound may be a metallic
soap, such as zinc stearate, zinc palmitate, zinc oleate, and lead
stearate.
[0098] In an exemplary embodiment, a photoconductor preferably
includes an organic compound having phenyl group in its surface,
and the peak Pa is preferably attributed to the phenyl group for
computing the evaluation index "Sb/Sa" for determining an
application amount of the protective agent. If the photoconductor
surface includes an organic compound having phenyl group, the
phenyl group can be detected at a wavenumber of 3055.+-.25
cm.sup.-1, which is closer to the wavenumber that the methylene
group is detected. Because the phenyl group and the methylene group
can be detected at wavenumbers (cm.sup.-1), closer to each other,
the projection depth of the light used for detection can be set to
values closer to each other, by which the evaluation index "Sb/Sa"
can be computed with a higher sensitivity and higher
reliability.
[0099] In general, materials used for detecting peaks, such as peak
Pa, may exist in a photoconductor with some concentration variation
in a depth direction of a photoconductive layer, and further other
materials, such as filler agent, may also be dispersed in a
photoconductor with some concentration variation in a depth
direction of a photoconductive layer. Accordingly, if the peak Pa
and the peak Pb can be detected at wavenumbers (cm.sup.-1), closer
to each other, the projection depth for each of the peak Pa and the
peak Pb can be set closer to each other, by which an effect of the
above-mentioned concentration variation to detection precision of
the peak Pa and the peak Pb can be reduced. Therefore, the closer
the projection depth of the peak Pa and the peak Pb, the more
reliable for obtaining better evaluation index "Sb/Sa."
[0100] Preferably, the photoconductor may not include a material,
which has a peak that overlaps with the peak attributed to phenyl
group, in its surface.
[0101] Further, in an exemplary embodiment, a photoconductor
preferably includes an organic compound having carbonate bond, and
the peak Pa is preferably attributed to the carbonate bond for
computing the evaluation index "Sb/Sa" for determining an
application amount of the protective agent. If the photoconductor
surface includes an organic compound having carbonate bond, the
photoconductor can preferably increase its strength. Further, if
the photoconductor surface includes an organic compound having
carbonate bond, the carbonate bond can be detected at a wavenumber
of 1760.+-.20 cm.sup.-1, which is closer to the wavenumber that the
methylene group is detected.
[0102] Because the carbonate bond and the methylene group can be
detected at wavenumbers (cm.sup.-1), closer to each other, the
projection depth of the light used for detection can be set to
values closer to each other, by which the evaluation index "Sb/Sa"
can be computed with a higher sensitivity and higher reliability.
Preferably, the photoconductor may not include a material, which
has a peak that overlaps with the peak attributed to carbonate
bond, in its surface.
[0103] In an exemplary embodiment, a protective layer setting unit
is evaluated as follows: a protective agent is applied to a
photoconductor for a given time, and if the evaluation index
"Sb/Sa" can be set to a given threshold value or less within a
given application time, such protective layer setting unit is
determined as acceptable, in which the evaluation index "Sb/Sa"
indicates application amount of the protective agent on the
photoconductor.
[0104] In an exemplary embodiment, a protective layer setting unit
includes a blade, a brush, and a protective agent bar as shown in
FIG. 7. A photoconductor and the brush are rotated at a given speed
by a drive mechanism, such as gears. The brush scrapes the
protective agent from the protective agent bar, and the protective
agent is then supplied to the photoconductor surface with a
rotation of the brush. The blade extends the protective agent over
the photoconductor when the photoconductor comes to a position
facing the blade, by which the protective agent is applied on the
photoconductor as a protective layer.
[0105] A description is now given to a configuration of a
protective layer setting unit, a method of evaluating the
protective layer setting unit, and a process cartridge or an image
forming apparatus having a protective layer setting unit according
to an exemplary embodiment.
[0106] A description is now given to a protective layer setting
unit according to an exemplary embodiment.
[0107] As background information, reason of abnormal image
occurrence in an image forming apparatus having a protective layer
setting unit was examined by observing a surface of photoconductor,
coated with the protective agent, with a scanning electron
microscope (SEM) under an assumption that an occurrence of the
abnormal image may be attributed to an amount of the protective
agent, such as abnormal image may occur where the protective agent
is not applied, and abnormal image may not occur where the
protective agent is applied. Although such surface observation
confirmed that the protective agent adhered on the photoconductor,
such SEM observation was not effective for determining an amount of
the protective agent on the photoconductor, by which reason of
abnormal image occurrence was not determined.
[0108] Another SEM observation was then conducted to determine
reason of abnormal image occurrence under an assumption that an
abnormal image may occur differently depending on image types to be
formed. Based on SEM observation for observing a portion of
photoconductor where abnormal image occurred, it was found that
when a formed image area was small, toner was more likely to adhere
the photoconductor, by which image resolution became lower, and
when a formed image area was great, the photoconductor was
partially abraded, by which abnormal image was more likely to
occur.
[0109] Because abnormal image occurs in various manners depending
on images to be formed, it is assumed that a surface condition of
photoconductor applied with a protective agent may be correlated to
occurring or not occurring abnormal image. In other words, an
application performance of protective agent by a protective layer
setting unit may be correlated to occurring or not occurring
abnormal image. In view of such background, an application amount
of the protective agent on the photoconductor is evaluated as
follows. Because conditions of protective agent on the
photoconductor change depending on formed images, an application
amount of the protective agent on the photoconductor is evaluated
without forming an image on the photoconductor.
[0110] As above noted, a conventional analysis method may not be
suitable for detecting an amount of a protective agent, such as
paraffin, not including metal component. In view of such
background, the ATR method using fourier transform infrared
spectrophotometer (FT-IR) is used for effectively evaluating a
surface condition of a photoconductor coated with a protective
agent not including metal component.
[0111] IR spectrum indicates a change of intensity profile of
sample with respect to a wavenumber (or wavelength) of an infrared
light source. Such IR spectrum profile is drawn as a curve profile
by setting wavenumber(cm.sup.-1), which is an inverse number of
wavelength in a horizontal axis and setting transmission factor (T)
or absorbance (a) in a vertical axis.
[0112] The transmission factor (T) is a ratio of light energy
entered a sample and light energy transmitted from the sample, and
the absorbance (a) is obtained by a process of common logarithm of
an inverse number of the transmission factor (T). Because the
absorbance is proportional to sample concentration (Lambert-Beer
law), peak intensity of absorbance spectrum is used for
quantitative determination of sample. As for a peak intensity of IR
spectrum, absorbance is preferably used for quantitative analysis
instead of the transmission factor.
[0113] In general, IR spectrum can be measured by two types of
machine: diffusion type infrared spectrophotometer and fourier
transform infrared spectrophotometer, wherein the fourier transform
infrared (FT-IR) spectrophotometer is mainly used for IR spectrum
be measurement with respect to higher efficiency on measurement
time, light energy usage, resolution power of wavenumber, and
precision of wavenumber. IR spectrum can be measured with such
machine using methods, such as a transmission method or the like,
which can be selected depending on a purpose of measurement, sample
shape, or the like. Among the measurement methods, the ATR method
is widely used for FT-IR measurement because the ATR method does
not need a complex sample treatment for IR spectrum
measurement.
[0114] In the ATR method, infrared absorption spectrum is measured
using total reflection. Specifically, an ATR prism having a higher
refractive index is closely contacted against a sample, an infrared
(IR) light is irradiated to the sample via the ATR prism, and then
an outgoing light from the ATR prism is analyzed spectrometrically.
The infrared light can be totally reflected at a contact face of
the ATR prism and the sample (i.e., total reflection) when the
infrared light is irradiated to the ATR prism with a given angle or
more, wherein such given angle is determined based on a
relationship of the refractive index of the ATR prism and the
sample. During such IR light irradiation, the IR light reflects
from an internal surface of the ATR prism and generates an
evanescent wave which projects orthogonally into the sample. Some
of the energy of the evanescent wave is absorbed by the sample and
the reflected IR light is attenuated and received by a detector, by
which absorption spectrum of the sample can be obtained.
[0115] The ATR method can be applied for various samples because an
absorption spectrum of the sample can be measured by contacting a
portion of the sample against the ATR prism. For example,
absorption spectrum of a thick sample or low-transmittance sample
can be measured if such sample can be closely contacted to the ATR
prism. In the ATR method, a functional group in the sample can be
determined based on wavenumber corresponding to absorbed infrared
light, and thereby the ATR method is widely used for qualitative
analysis. However, because a peak intensity of absorption spectrum
is varied due to a press-down pressure of sample, the ATR method
may not be used so often for quantitative analysis in general.
[0116] In an exemplary embodiment, the ATR method is used for
quantitative analysis for evaluating an application amount of a
protective agent on a photoconductor by measuring and analyzing IR
spectrum under various conditions.
[0117] In an exemplary embodiment, an attenuated total reflection
method (hereinafter, referred as ATR method or ATR) is used to
evaluate a protective agent not including metal component, such as
paraffin applied to a photoconductor. In the ATR method, a
projection depth of infrared (IR) light into a sample becomes
different depending on measurement conditions, such as ATR prism,
incident angle, by which results of measured spectrum of a same
sample may become different depending on such measurement
conditions. For example, one spectrum result shows only a peak
attributed to a photoconductor, another spectrum result shows only
a peak attributed to a protective agent, or another spectrum result
shows a mixture of a peak attributed to a photoconductor and a peak
attributed to a protective agent.
[0118] In an exemplary embodiment, a measurement condition which
can detect both of a peak attributed to a photoconductor and a peak
attributed to a protective agent is determined based on researches
on measurement conditions, in which conditions of the ATR prism,
incident angle, or the like are changed in many values. Under such
measurement condition, an infrared (IR) spectrum profile for a
photoconductor is measured to evaluate an application amount of the
protective agent on the photoconductor.
[0119] In the ATR method, a measurement portion of a sample deforms
due to a pressure for holding the sample, by which peak intensity
of spectrum may vary. Accordingly, peak intensity of spectrum alone
may not be used for effectively detecting a surface condition of
the sample.
[0120] In view of such variation of measurement results, a
substantially consistent condition is set when setting a sample on
a measurement device so as to obtain infrared (IR) spectrum profile
under the consistent condition. Specifically, a gap between a
fixing jig for holding the sample and the ATR prism is maintained
at a consistent level, or a pressure for holding the sample is
maintained at a consistent level. Then, a measurement of infrared
(IR) spectrum profile is conducted for a photoconductor applied
with the protective agent, and each peak in the IR spectrum profile
is evaluated and attributed to a specific material, functional
group, or the like. In an exemplary embodiment, an area ratio
between a peak area attributed to photoconductor an a peak area
attributed to protective agent is computed, wherein the peak area
ratio becomes greater as an application time of the protective
agent increases.
[0121] In an exemplary embodiment, a peak area attributed to
photoconductor and a peak area attributed to protective agent are
used to evaluate an application amount of the protective agent on
the photoconductor.
[0122] As described later in this disclosure, when an peak area
ratio between a peak area attributed to a photoconductor and a peak
area attributed to protective agent is set within a given range,
higher quality images can be formed, in which an area ratio of peak
area attributed to protective agent with respect to a peak area
attributed to a photoconductor is used as evaluation index for
evaluating an application amount of a protective agent on a
photoconductor.
[0123] In an exemplary embodiment, an application amount of the
protective agent applied to a surface of a photoconductor is
evaluated as follows. As above mentioned, the protective layer
setting unit is used to apply the protective agent, such as
paraffin, to the surface of photoconductor. The ATR method using
infrared absorption spectrum uses an ATR prism made of germanium
(Ge) and incident angle of infrared light of 45.degree. as
measurement condition, for example. Specifically, an IR spectrum A
of the photoconductor surface before applying the protective agent
and an IR spectrum B of the protective agent alone are measured by
the ATR method using infrared absorption spectrum, and an IR
spectrum C after applying the protective agent on the
photoconductor is measured by the ATR method.
[0124] FIG. 8 shows the IR spectrum A (absorbance spectrum) for a
photoconductor surface before applying the protective agent, the IR
spectrum B (absorbance spectrum) for a protective agent alone, the
IR spectrum C (absorbance spectrum) for a photoconductor surface
after applying a protective agent, and differential spectrum D,
obtained by subtracting the IR spectrum A from the IR spectrum
C.
[0125] The IR spectrum A has a given specific peak that is not
included in the IR spectrum B, which is termed as a peak Pal and
such peak Pa1 has a peak area Sa1 at a wavenumber of 1770
cm.sup.-1. The IR spectrum B has a given specific peak that is not
included in the IR spectrum A, which is termed as a peak Pb1 and
such peak Pb1 has a peak area Sb1 at a wavenumber of 2850
cm.sup.-1. The application amount of the protective agent on the
photoconductor is evaluated using a peak area ratio "Sb1/Sa1." In
an exemplary embodiment, the peak area ratio "Sb1/Sa1" is
preferably set to 0.02 or more after applying the protective agent
on the photoconductor for 5 minutes, and the peak area ratio
"Sb1/Sa1" is preferably set to 0.85 or less after applying the
protective agent on the photoconductor for 150 minutes. The peak
Pb1 is a peak attributed to protective agent, and most of IR
spectrum peaks of an organic photoconductor (OPC) are detected
around the peak Pb1. Accordingly, the peak area Sb1 of the Pb1 is
computed using a differential spectrum, in which IR spectrum A is
subtracted from IR spectrum C.
[0126] Further, in an exemplary embodiment, another peaks may be
used in a similar manner.
[0127] Specifically, the IR spectrum A has a given specific peak
that is not included in the IR spectrum B, which is termed as a
peak Pa2 and such peak Pa2 has a peak area Sa2 at a wavenumber of
3040 cm.sup.-1. The IR spectrum B has a given specific peak that is
not included in the IR spectrum A, which is termed as a peak Pb2
and such peak Pb2 has a peak area Sb2 at a wavenumber of 2920
cm.sup.-1. The application amount of the protective agent on the
photoconductor is evaluated using a peak area ratio "Sb2/Sa2." In
an exemplary embodiment, the peak area ratio "Sb2/Sa2" is
preferably set to 6.5 or more after applying the protective agent
on the photoconductor for 15 minutes, and the peak area ratio
"Sb2/Sa2" is preferably set to 38 or less after applying the
protective agent on the photoconductor for 120 minutes.
[0128] In the ATR method, infrared light is not reflected on a
boundary face of a sample and an ATR prism, but infrared light
projects into an internal portion of a sample (or projects for a
projection depth in a sample) and then reflects as total reflection
from the projection depth. The projection depth of infrared light
is a distance from a surface of a sample, wherein an infrared light
intensity at such distance becomes 1/e of an infrared light
intensity on the surface of the sample, which is defined by the
aforementioned equation 1. As indicated in the equation 1, the
projection depth of infrared light to the sample is determined by
incident angle, refractive index of ATR prism, and wavelength.
Specifically, the greater the incident angle .theta., the greater
the refractive index of ATR prism, or the smaller the measurement
wavelength, the projection depth becomes smaller. If a smaller
projection depth is used, a condition closer to the surface of the
sample can be obtained as IR spectrum.
[0129] Specifically, the ATR prism may be germanium (Ge) prism
having a higher refractive index to obtain condition information
closer to the surface of the sample, which is a photoconductor
coated with the protective agent. Further, an incident angle of
infrared light to the sample is set to 45.degree. so as to obtain
the evaluation index "Sb/Sa" more precisely. With such condition of
using a germanium (Ge) prism as the ATR prism and setting the
incident angle of infrared light to 45.degree., an application
amount of the protective agent on the photoconductor by the
protective layer setting unit can be determined more precisely
using the evaluation index "Sb/Sa."
[0130] The peak Pb1 and Pb2 are peaks attributed to methylene
group, which is detectable having a sufficient intensity.
Accordingly, the peak Pb1 and Pb2 can be preferably used as index
peak for evaluating an application amount of the protective agent
on the photoconductor. Further, the peak Pa1 and Pa2 are peaks
attributed to polycarbonate bond included in a photoconductor,
which is detectable having a sufficient intensity. Accordingly, the
peak Pa1 and Pa2 can be preferably used as index peak for
evaluating an application amount of the protective agent on the
photoconductor, which has polycarbonate. Because the peak Pa2 and
the peak Pb2 can be detected at wavenumbers (cm.sup.-1), closer to
each other, the projection depth of the light used for detection
can be set to values closer to each other, by which the evaluation
index "Sb/Sa" can be preferably computed with a higher sensitivity
and higher reliability. Further, as for computing a peak area of IR
spectrum, absorbance is preferably used for quantitative
analysis.
[0131] In the FT-IR analysis, an application amount of the
protective agent on the photoconductor may be evaluated by just
observing a peak intensity (or area) attributed to a protective
agent. However, in the ATR method, it is hard to effectively
evaluate an application amount of the protective agent on the
photoconductor by just using peak intensity (or area) alone because
the peak area may vary due to a variation of pressure for holding a
sample. Instead, a peak area ratio between a peak area attributed
to a protective agent and a peak area attributed to a
photoconductor is used for evaluating an application amount of the
protective agent to the photoconductor so as to conduct an
evaluation of an application amount of the protective agent more
reliably. Such peak area ratio "Sb/Sa" is used as an evaluation
index.
[0132] The peak Pa (Pa1, Pa2) in the IR spectrum C is one peak in
the IR spectrum A, which is not detected in the IR spectrum B. In
FIG. 1, the peak Pa of the IR spectrum A has a wavenumber, which is
not detected in the IR spectrum B. In other words, a peak is not
detected in the IR spectrum B at the wavenumber that the peak Pa is
detected in the IR spectrum A. If a peak is detected in both of the
IR spectrum A and the IR spectrum B at a same wavenumber as shown
in FIG. 2, such peak (peak M in FIG. 2) is not preferably used for
computing the peak area ratio or evaluation index "Sb/Sa."
[0133] Preferably, as shown in FIG. 3, the peak Pa in the IR
spectrum A and a given specific peak (peak K) in the IR spectrum B
have no overlapping area. In other words, it is preferable that the
peak Pa and the peak K do not overlap each other at peak top or
tail of each peak. If the peak Pa and the peak K overlap each other
at peak top or tail of each peak as shown in FIG. 1, a differential
spectrum of the IR spectrum C and the IR spectrum B needs to be
computed, in which a peak area of the peak K is subtracted from the
IR spectrum C to obtain a correct value of the peak Pa, by which
the peak area ratio "Sb/Sa" can be computed effectively by
eliminating an effect of the peak K of the IR spectrum B.
[0134] However, such subtraction step can be omitted if the peak Pa
has an area, which is too great compared to the peak K, even if the
peak Pa and the peak K overlap each other at peak top or tail of
each peak as shown in FIG. 1. If such subtraction step can be
omitted, a computation of the peak area ratio "Sb/Sa" can be
simplified and a computation can be conducted more precisely.
[0135] The peak Pb (Pb1, Pb2) in the IR spectrum C is one peak in
the IR spectrum B, which is not detected in the IR spectrum A. In
FIG. 4, the peak Pb of the IR spectrum B has a wavenumber, which is
not detected in the IR spectrum A. In other words, a peak is not
detected in the IR spectrum A at the wavenumber that the peak Pb is
detected in the IR spectrum B. If a peak is detected in both of the
IR spectrum A and the IR spectrum B at a same wavenumber as shown
in FIG. 5, such peak (peak N in FIG. 5) is not preferably used for
computing the peak area ratio "Sb/Sa."
[0136] Preferably, as shown in FIG. 6, the peak Pb in the IR
spectrum B and a given specific peak (peak L) in the IR spectrum A
have no overlapping area. In other words, it is preferable that the
peak Pb and the peak L do not overlap each other at peak top or
tail of each peak. If the peak Pb and the peak L overlap each other
at peak top or tail of each peak as shown in FIG. 4, a differential
spectrum of the IR spectrum C and the IR spectrum A needs to be
computed, in which a peak area of the peak L is subtracted from the
IR spectrum C to obtain a correct value of the peak Pb, by which
the peak area ratio "Sb/Sa" can be computed effectively by
eliminating an effect of the peak L of the IR spectrum A.
[0137] However, such subtraction step can be omitted if the peak Pb
has an area, which is too great compared to the peak L, even if the
peak Pb and the peak L overlap each other at peak top or tail of
each peak as shown in FIG. 4. If such subtraction step can be
omitted, a computation of the peak area ratio "Sb/Sa" can be
simplified and a computation can be conducted more precisely.
[0138] As above described, the peak area ratio "Sb1/Sa1" is set to
0.020 or more after applying the protective agent on the
photoconductor for 5 minutes, preferably from 0.040 to 0.3, and
more preferably from 0.045 to 0.2. If the Sb1/Sa1 is too small
after the application time of 5 minutes, the protective agent may
not effectively protect the photoconductor at an earlier stage (or
initial usage timing) of an image forming apparatus, which is not
preferable. Further, as above described, the peak area ratio
"Sb1/Sa1" is set to 0.85 or less after applying the protective
agent on the photoconductor for 150 minutes, preferably from 0.1 to
0.6, and more preferably from 0.15 to 0.4. If the Sb1/Sa1 becomes
too great within the application time of 120 minutes, the
protective agent may be excessively applied to the photoconductor,
by which the photoconductor may not be charged effectively, or an
image blur may occur, which is not preferable.
[0139] As above described, the peak area ratio "Sb2/Sa2" is set to
6.5 or more after applying the protective agent on the
photoconductor for 15 minutes, preferably from 7 to 23, and more
preferably from 8 to 15. If the Sb2/Sa2 is too small after the
application time of 15 minutes, the protective agent may not
effectively protect the photoconductor at an earlier stage (or
initial usage timing) of an image forming apparatus, which is not
preferable. Further, as above described, the peak area ratio
"Sb2/Sa2" is set to 38 or less after applying the protective agent
on the photoconductor for 120 minutes, preferably from 8 to 25, and
more preferably from 9 to 16. If the Sb2/Sa2 becomes too great
after the application time of 120 minutes, the protective agent may
be excessively applied to the photoconductor, by which the
photoconductor may not be charged effectively, or an image blur may
occur, which is not preferable.
[0140] In an exemplary embodiment, the protective layer setting
unit uses a protective agent having paraffin for 50 to 95 weight
percent (wt %). The ratio of paraffin in the protective agent is a
ratio of paraffin of all organic constituents in the protective
agent. If the protective agent includes inorganic constituent, the
ratio of paraffin is a ratio of paraffin of all organic
constituents in the protective agent computed by excluding
inorganic constituent.
[0141] Although a threshold value for evaluation index "Sb1/Sa1"
may vary depending on a ratio of paraffin in a protective agent,
the peak area ratio "Sb1/Sa1" can be set 0.020 or more after
applying the protective agent on the photoconductor for 5 minutes,
and the peak area ratio "Sb1/Sa1" can be set 0.85 or less after
applying the protective agent on the photoconductor for 150
minutes, wherein such value indicates that an application amount of
the protective agent to the photoconductor is in good level.
[0142] Although a threshold value for evaluation index "Sb2/Sa2"
may vary depending on a ratio of paraffin in a protective agent,
the peak area ratio "Sb2/Sa2" can be set 6.5 or more after applying
the protective agent on the photoconductor for 15 minutes, and the
peak area ratio "Sb2/Sa2" can be set 38 or less after applying the
protective agent on the photoconductor for 120 minutes, wherein
such value indicate that an application amount of the protective
agent to the photoconductor is in good level.
[0143] In an exemplary embodiment, the protective layer setting
unit uses a protective agent having paraffin as main component, for
example. Such paraffin includes normal paraffin, and isoparaffin,
for example, which can be used alone or in combination. In an
exemplary embodiment, a protective agent, used as a protective
agent bar, includes paraffin with 50 wt % (weight percent) or more,
more preferably 60 wt % or more, and further preferably 70 wt % or
more, for example. If the paraffin amount included in the
protective agent is too small, a photoconductor may not be
effectively protected by the protective agent, by which the
photoconductor may be abraded during image forming, which is not
preferable. If the paraffin amount included in the protective agent
is too great, the photoconductor surface may not be effectively
coated by paraffin, which is not preferable. In general, it is
difficult to form a uniform thin layer of paraffin on a
photoconductor by using a brush or blade pressure if only paraffin
is used as a protective agent. Therefore, a protective agent may
need to include paraffin and other material.
[0144] Such other material may be amphipathic organic compound;
hydrocarbons, such as aliphatic unsaturated hydrocarbon, alicyclic
saturated hydrocarbon (e.g., cyclo paraffin, cyclic polyolefin),
alicyclic unsaturated hydrocarbon, aromatic hydrocarbon;
fluorocarbon polymer or wax, such as PTFE
(polytetrafluoroethylene), PFA (perfluoroalkoxy), FEP (fluorinated
ethylene-propylene), PVDF (polyvinylidene fluoride), ETFE (Ethylene
tetrafluoroethylene); silicone polymer or wax, such as polymethyl
silicone, polymethylphenyl silicone; inorganic compound having
lubricating property, such as mica isinglass, but not limited to
these. Among these, amphipathic organic compound and alicyclic
saturated hydrocarbon are preferably included in a protective agent
to enhance an application performance of protective agent, and
alicyclic saturated hydrocarbon, such as cyclic polyolefin is
preferably used to form a uniform layer of protective agent on a
photoconductor. These materials can be used alone or in
combination.
[0145] Such amphiphilic organic compound may be anionic surfactant,
cationic surfactant, zwitterionic surfactant, nonionic surfactant,
or a complex compound of these, for example. Because a protective
agent is applied to a photoconductor used for image forming, such
protective agent may need to have a property that does not cause a
problem on electric property of the photoconductor. The nonionic
surfactant, which is an amphiphilic organic compound, may not be
ionic dissociated, and thereby electric charge leak by aerial
discharge can be reduced and image quality can be maintained at a
higher level even if environmental condition, such as humidity,
changes greatly.
[0146] The nonionic surfactant may preferably be an ester compound
of alkylcarboxylic acid (see chemical formula (1)) and polyalcohol,
in which "n" is an integral number from 15 to 35.
C.sub.nH.sub.2n+1COOH (chemical formula(1))
[0147] If a straight chain alkylcarboxylic acid is used as
alkylcarboxylic acid (chemical formula(1)), amphiphilic organic
compound can be preferably adhered on a surface of an image
carrying member such as photoconductor. Specifically,
hydrophobicity portion of the amphiphilic organic compound can be
oriented to a surface of an image carrying member in an orderly
manner, and thereby the amphiphilic organic compound can be
preferably adsorbed on the image carrying with a higher adsorption
density.
[0148] Alkylcarboxylic acid ester has hydrophobicity. The greater
the number of alkylcarboxylic acid ester in one molecule, the more
effective to reduce an adsorption of dissociated material generated
by aerial discharge to a surface of an image carrying member such
as photoconductor, and the more effective to reduce a electrical
stress to a surface of the image carrying member during a charging
process. However, if a ratio of alkylcarboxylic acid ester becomes
too great, polyalcohol having hydrophilicity may be blocked by the
alkylcarboxylic acid ester, by which an adsorption performance may
not be effectively obtained depending on a surface condition of an
image carrying member. Accordingly, the average number of ester
bond in one molecule of amphiphilic organic compound may be
preferably from 1 to 3.
[0149] Such average number of ester bond in one molecule of
amphiphilic organic compound can be set or adjusted by selecting
one amphiphilic organic compound or by mixing a plurality of
amphiphilic organic compounds, each compound having different
number of ester bonds. Such amphiphilic organic compound may
include anionic surfactant, cationic surfactant, zwitterionic
surfactant, and nonionic surfactant, as above described.
[0150] Examples of the anionic surfactant include compounds of
alkali metal ion (e.g., sodium, potassium), alkaline-earth metal
ion (e.g., magnesium, calcium), metal ion (e.g., aluminum, zinc),
or ammonium ion bonded with a compound having an anion at
hydrophobicity portion, such as alkyl benzene sulfonate,
.alpha.-olefin sulfonate, alkane sulfonate, sulfuric alkyl salt,
sulfuric alkylpolyoxyethylene salt, alkyl phosphate salt,
long-chain aliphatic acid salt, .alpha.-sulfoaliphatic acid ester
salt, and alkyl ether sulfate.
[0151] Examples of the cationic surfactant include compounds
composed of chlorine, fluorine, bromine, phosphoric ion, nitrate
ion, sulphuric ion, thiosulphuric ion, carbonate ion, and hydroxide
ion, which are bonded to a compound having a cation at
hydrophobicity portion, such as alkyltrimethyl ammonium salt,
dialkylmethyl ammonium salt, and alkyldimethylbenzyl ammonium
salt.
[0152] Examples of the zwitterionic surfactant include
dimethylalkylamine oxide, N-alkylbetaine, imidazoline derivatives,
and alkylamino acid.
[0153] Examples of the nonionic surfactant include alcohol
compound, ether compound, or amide compound, such as long-chain
alkylalcohol, alkylpolyoxyethylene ether, polyoxyethylene alkyl
phenyl ether, aliphatic acid diethanolamide, alkyl polyglucoxide,
and polyoxyethylene sorbitan alkylester. Further, examples of the
nonionic surfactant preferably include long-chain alkylcarboxylic
acid, such as lauric acid, paltimic acid, stearic acid, behenic
acid, lignoceric acid, cerinic acid, montanic acid, melissic acid;
polyalcohol, such as ethylene glycol, propylene glycol, glycerin,
erythritol, hexitol; and ester compound having partially anhydride
compound of these.
[0154] Examples of ester compounds include alkylcarboxylic acid
glyceryl or its substitution, such as monoglyceryl stearate,
diglyceryl stearate, monoglyceryl palmitate, diglyceryl laurate,
triglyceryl laurate, diglyceryl palmitate, triglyceryl palmitate,
diglyceryl myristate, triglyceryl myristate, glyceryl
palmitate/stearate, monoglyceryl arachidate, diglyceryl arachidate,
monoglyceryl behenate, glyceryl stearate/behenate, glyceryl
cerinate/stearate, monoglyceryl montanate, monoglyceryl melissate;
and alkylcarboxylic acid sorbitan or its substitution, such as
monosorbitan stearate, trisorbitan stearate, monosorbitan
palmitate, disorbitan palmitate, trisorbitan palmitate, disorbitan
myristate, trisorbitan myristate, sorbitan paltimate/stearate,
monosorbitan arachidate, disorbitan arachidate, monosorbitan
behenate, sorbitan stearate/behenate, sorbitan cerinate/stearate,
monosorbitan montanate, monosorbitan melissate, but not limited
those. These amphiphilic organic compound can be used alone or in
combinaton.
[0155] Further, the protective agent may be included with filler,
such as metal oxides, silicate compound, mica isinglass, boron
nitride, as required.
[0156] A description is now given to a configuration of a
protective layer setting unit according to an exemplary embodiment.
FIG. 9 illustrates a schematic configuration of an image forming
engine, in which a protective layer setting unit 2 is schematically
shown with a photoconductor drum 1 used as an image carrying member
and a cleaning unit 4. The protective layer setting unit 2 is
opposed to the photoconductor drum 1. The protective layer setting
unit 2 includes an agent bar 21, an agent applicator 22, a biasing
force applicator 23, a layer adjusting unit 24, and a support guide
25, for example.
[0157] The agent bar 21 may be a block of protective agent, which
may be made by melting and/or compressing a protective agent in a
given shape such as bar shape (e.g., circular, quadrangular,
hexagonal shape). Such protective layer setting unit 2 can be used
as an "application unit" for applying a protective agent onto the
photoconductor drum 1. The agent applicator 22 includes a brush 22a
that contacts the agent bar 21 and supplies the protective agent to
the photoconductor drum 1. The biasing force applicator 23 presses
the agent bar 21 against the brush 22a of the agent applicator 22
to transfer the protective agent to the brush 22a. The layer
adjusting unit 24 is used to form a thin layer of the protective
agent on the photoconductor. The support guide 25 supports the
agent bar 21 so as to prevent shaking of the agent bar 21. In an
exemplary embodiment, the agent bar 21 can be prepared by a
melt-casting method or a compression casting method. In the
melt-casting method, a protective agent is melted and poured in a
cast, and then cooled. In the compression casting method, powder of
protective agent is compressed. The cleaning unit 4 includes a
cleaning member 41, and a biasing device 42, for example.
[0158] The agent bar 21 is pressed against the brush 22a of the
agent applicator 22 using a biasing force of the biasing force
applicator 23 to transfer the protective agent from the agent bar
21 to the brush 22a, wherein the agent applicator 22 may be formed
as brush roller, and the biasing force applicator 23 may include a
spring, for example. The agent applicator 22, rotating at a given
speed having a different linear velocity with respect to the
photoconductor drum 1, slidably contacts the photoconductor drum 1
to apply the protective agent to the surface of the photoconductor
drum 1 from the brush 22a, which has the protective agent
transferred from the agent bar 21. The protective agent supplied to
the photoconductor drum 1 may be indefinite-shaped particles.
Depending on material types of protective agent, a protective layer
may not be effectively and uniformly formed on the photoconductor
drum 1 just by applying the protective agent. In light of such
situation, the layer adjusting unit 24 having a layer forming
device 24a and a biasing member 24b is used to form a protective
layer uniformly on the photoconductor drum 1. The layer forming
device 24a may be a blade (hereinafter, blade 24a), and the biasing
member 24b, such as spring, presses the blade 24a against the
photoconductor drum 1.
[0159] With such configuration, the photoconductor drum 1 can be
supplied with a protective agent sufficiently, and a uniform
protective layer can be effectively formed on the photoconductor
drum 1 by the layer adjusting unit 24. Accordingly, a contamination
caused by a charging device, such as charge roller, may be reduced,
and thereby abnormal image may not be produced. Further,
replacement of consumable parts can be reduced, and higher quality
image can be produced over time.
[0160] Instead of using the agent bar 21, powders of protective
agent can be directly supplied to a surface of the photoconductor
drum 1. In this case, the agent bar 21, the agent applicator 22,
and the biasing force applicator 23 can be omitted from the process
cartridge PC, and a container for containing powders of protective
agent and a powder transport unit for transporting protective agent
powders are disposed. The powder transport unit may be a known
transport unit, such as pump, auger, or the like.
[0161] The blade 24a may be made of a known elastic body, such as
urethane rubber, hydrin rubber, silicone rubber, fluorocarbon
rubber, or the like, which can be used alone or mixed. Such blade
24a may be coated with a material having a lower frictional
coefficient to reduce friction at a contact portion with the
photoconductor drum 1, wherein the blade 24a may be coated with
such material by a dipping method or the like. Further, to adjust
hardness of the elastic body, fillers such as organic filler or
inorganic filler can be dispersed in the elastic body.
[0162] Such blade 24a is fixed to a blade supporter 24c using
adhesive or fused directly to the blade supporter 24c so that a
leading edge of the blade 24a can be effectively pressed against
the photoconductor drum 1 with a given pressure. The blade 24a has
a thickness of from 0.5 mm to 5 mm, and preferably from 1 mm to 3
mm, for example, wherein the thickness of the blade 24a is
determined in view of pressure biased to the blade 24a. The blade
24a has a free length portion of from 1 mm to 15 mm, and preferably
from 2 mm to 10 mm, for example, wherein the free length of the
blade 24a is also determined in view of pressure biased to the
blade 24a. The free length portion is a flexibly bend-able portion,
not attached to the blade supporter 24c.
[0163] Alternatively, the blade 24a can be made of a resilient
metal and an elastic material formed on the resilient metal by a
coating method or a dipping method using a coupling agent or a
primer component. Further, a thermosetting process may be conducted
for such blade 24a made of a resilient metal and an elastic
material. Further, such blade 24a may be subjected to a surface
polishing process. The resilient metal may be a sheet spring, and
the elastic material may be resin, rubber, elastomer, or the like.
The resilient metal has a thickness of from 0.05 mm to 3 mm, and
preferably from 0.1 mm to 1 mm, for example. Further, the blade 24a
made from the resilient metal may be bended in a direction parallel
to a support direction after fixing the blade 24a to the blade
supporter 24c to prevent twisting of the blade 24a. The surface
layer of the blade 24a may be fluorocarbon polymer, such as PFA
(perfluoroalkoxy), PTFE (polytetrafluoroethylene), FEP (fluorinated
ethylene-propylene), PVDF (polyvinylidene fluoride), fluorocarbon
rubber; and silicone elastomer, such as methylphenyl silicone
elastomer, but not limited to these. These can be used alone or
used with filler material, as required.
[0164] Further, the blade 24a may be pressed against the
photoconductor drum 1 by the biasing member 24b with a linear load
of preferably from 5 gf/cm to 80 gf/cm, more preferably from 10
gf/cm to 60 gf/cm, which is effective for extending and forming a
protective layer on the photoconductor drum 1.
[0165] A description is now given to the agent applicator 22. The
agent applicator 22 may preferably be a brush roller having a
number of brush fibers (i.e., brush 22a), used for supplying a
protective agent to the photoconductor drum 1. Such brush fibers
(i.e., brush 22a) have a given level of flexibility to reduce or
reduce mechanical stress to be applied to a surface of the
photoconductor drum 1.
[0166] Such brush fibers having some flexibility may be made of
known materials having flexibility, such as polyolefin resin (e.g.,
polyethylene, polypropylene); polyvinyl resin and polyvinylidene
resin (e.g., polystyrene, acrylic resin, polyacrylonitrile,
polyvinyl acetate, polyvinyl alcohol, polyvinyl butyral, polyvinyl
chloride, polyvinyl carbazole, polyvinyl ether, polyvinyl ketone);
copolymer of polyvinyl chloride/vinyl acetate; copolymer of
styrene/acrylic acid; styrene/butadiene resin; fluorocarbon polymer
(e.g., polytetrafluoroethylene, polyvinyl fluoride, polyvinylidene
fluoride, polychlorotrifluoroethylene); polyester; nylon; acrylic;
rayon; polyurethane; polycarbonate; phenol resin; and amino resin
(e.g., urea/formaldehyde resin, melamine resin, benzog anamine
resin, urea resin, polyamide resin), for example. Such materials
can be used alone or in combination. Further, to adjust flexibility
of brush fibers, diene rubber, styrene-butadiene rubber (SBR),
ethylene-propylene rubber, isoprene rubber, nitrile rubber,
urethane rubber, silicone rubber, hydrin rubber, and norbomene
rubber, or the like can be added.
[0167] Such brush 22a used as the agent applicator 22 have a core
metal 22b and brush fibers formed on the core metal 22b by winding
brush fibers in a spiral manner, for example. Such brush fibers may
have a fiber diameter of from 10 .mu.m to 500 .mu.m, and more
preferably from 20 .mu.m to 300 .mu.m. If the fiber diameter is too
small, a supplying or applying speed of a protective agent becomes
too slow.
[0168] If the fiber diameter is too great, the number of brush
fibers per unit area becomes small, by which brush fibers may not
contact the photoconductor drum 1 uniformly. If the brush fibers do
not contact the photoconductor drum 1 uniformly, a protective agent
may not be uniformly applied to a surface of the photoconductor
drum 1. Further, if the fiber diameter is too great, brush fibers
may be more likely to cause damages to the photoconductor drum 1.
Further, if the fiber diameter is too great, brush fibers may
scrape a protective agent with a greater force, by which a lifetime
of the protective agent becomes shorter. Further, if the fiber
diameter is too great, brush fibers may supply a protective agent
having relatively larger sized particles to the photoconductor drum
1, by which such particles may adhere and contaminate a charge
roller. Further, if the fiber diameter is too great, a greater
torque may be required to rotate the brush roller or the
photoconductor drum 1, which is not preferable.
[0169] Such brush fiber has a fiber length of from 1 mm to 15 mm,
and more preferably from 3 mm to 10 mm. If the length of brush
fiber is too small, the core metal of the agent applicator 22 may
be disposed too close to the photoconductor drum 1, by which the
core metal 22b may contact and cause damages to the photoconductor
drum 1, which is not preferable. If the length of brush fiber is
too great, brush fibers may scrape a protective agent with a
smaller force and brush fibers may contact the photoconductor drum
1 with a smaller force, in which the protective agent may not be
effectively applied to the photoconductor drum 1 and the brush
fibers may be more likely to drop from the core metal 22b, which
are not preferable.
[0170] Such brush fiber has a fiber density of 10,000 to 300,000
fibers per square inch (or 1.5.times.10.sup.7 to 4.5.times.10.sup.8
fibers per square meter). If the fiber density is too small, a
protective agent may not be uniformly applied to a surface of the
photoconductor drum 1, or the protective agent may not be
effectively applied to the photoconductor drum 1, which are not
preferable. If the fiber density is too great, a diameter of brush
fiber may need to be set to a significantly smaller size, which is
not preferable.
[0171] Such brush roller preferably has a higher fiber density to
uniformly and reliably apply a protective agent to the
photoconductor drum 1, in which one brush fiber may be preferably
made of a bundle of tiny fibers such as several to hundreds of tiny
fibers. For example, one brush fiber may be composed of a bundle of
50 tiny fibers, in which one tiny fiber has 6.7 decitex (6 denier)
and a bundle of 50 filaments has a value of 333 decitex computed by
a equation of 6.7 decitex.times.50 filament (or 300 denier=6
denier.times.50 filament).
[0172] Such brush fiber is preferably made of single fiber having a
diameter of 28 .mu.m to 43 .mu.m, more preferably 30 .mu.m to 40
.mu.m, to effectively and efficiently supply a protective agent.
Because brush fibers are generally made by twisting fibers, brush
fibers may not have a uniform fiber diameter, and thereby a unit of
"denier" and "decitex" are used in general. However, if a single
fiber is used as one brush fiber, brush fibers have a uniform fiber
diameter, and thereby brush fibers may be preferably defined by a
fiber diameter. If the single fiber has too small diameter, a
protective agent may not be efficiently supplied, which is not
preferable. If the single fiber has too great diameter, the single
fiber has too great stiffness, by which the photoconductor drum 1
may be damaged, which is not preferable.
[0173] Further, such single fiber having a diameter of 28 .mu.m to
43 .mu.m is preferably implanted to a surface of the core metal 22b
in a perpendicular direction, and electrostatic implantation method
using electrostatic force may be preferably used to implant brush
fibers on the core metal. In an electrostatic implantation method,
an adhesive agent is applied to the core metal 22b, and then the
core metal 22b is charged. Under such charged condition, a number
of single fibers are dispersed in a space using electrostatic
force, and then implanted on the core metal 22b applied with the
adhesive agent. The adhesive agent is hardened after such
implantation to form a brush roller. As such, a brush roller having
a fiber density of 50,000 to 600,000 fibers per square inch can be
made by an electrostatic implantation method.
[0174] Further, such brush fiber (i.e., brush 22a) may have a coat
layer on a surface of fiber, as required, to stabilize a surface
shape and fiber property against environmental effect, for example.
The coat layer may be made of material, which can change its shape
when brush fibers flex. Such material having flexibility may be
polyolefin resin (e.g., polyethylene, polypropylene, chlorinated
polyethylene, chlorosulfonated polyethylene); polyvinyl and
polyvinylidene resin such as polystyrene, acrylic resin (e.g.,
polymethyl methacrylate), polyacrylonitrile, polyvinyl acetate,
polyvinyl alcohol, polyvinyl butyral, polyvinyl chloride, polyvinyl
carbazole, polyvinyl ether, polyvinyl ketone; copolymer of
polyvinyl chloride/vinyl acetate; silicone resin or its modified
compound having organosiloxane bonding (e.g., modified compound of
alkyd resin, polyester resin, epoxy resin, polyurethane);
fluorocarbon resin, such as perfluoro alkylether, polyfluorovinyl,
polyfluorovinylvinyliden, polychlorotrifluoroethylene; polyamide;
polyester; polyurethane; polycarbonate; amino resin, such as
urea/formaldehyde resin; and epoxy resin, for example. These
materials can be used alone or in combination.
[0175] Hereinafter, a process cartridge (or image forming engine)
according to an exemplary embodiment is explained with reference to
FIG. 10. The process cartridge according to an exemplary embodiment
includes the above described photoconductor applied with a
protective agent, a charging unit for uniformly charging the
photoconductor, a developing unit for developing a latent image
formed on the surface of photoconductor as toner image using a
developing agent having toner, and a protective layer setting unit
used for applying the protective agent to the photoconductor.
[0176] Specifically, the process cartridge 10 may be termed as an
image forming engine 10. FIG. 10 illustrates a schematic
configuration of the image forming engine 10, which includes the
photoconductor drum 1, the protective layer setting unit 2, a
charge roller 3, the cleaning unit 4, and a development unit 5, for
example. Such image forming engine 10 may be disposed proximity to
a transfer roller 6 and a intermediate transfer member 7, such as
transfer belt. The photoconductor drum 1 can be supplied with a
protective agent as above-described using the protective layer
setting unit 2, which is disposed between the cleaning unit 4 and
the charge roller 3. The cleaning unit 4 removes toner remaining on
the photoconductor drum 1 after an image transfer process. In an
exemplary embodiment, the cleaning unit 4 cleans the photoconductor
surface before applying the protective agent to the photoconductor
drum 1 to apply the protective agent at a good surface condition.
Accordingly, the cleaning unit 4 may be one part of the protective
layer setting unit 2.
[0177] The charge roller 3 may use a direct current charging method
or an AC charging method, but preferably use the AC charging
method, which superimposes direct-current voltage on
alternating-current voltage using a high voltage power source (not
shown).
[0178] The development unit 5 includes a developing roller 51, and
agitation transport screws 52 and 53, for example. The developing
roller 51 carries and transports a developing agent, such as
one-component developing agent not having carrier, and
two-component developing agent having toner and carrier, and the
agitation transport screws 52 and 53 agitate and transport the
developing agent. As above described with reference to FIG. 9, the
protective layer setting unit 2 includes the agent bar 21, the
agent applicator 22, the biasing force applicator 23, the layer
adjusting unit 24, and the support guide 25, for example.
[0179] After conducting a transfer process, partially degraded
protective agent or toner remaining on the surface of the
photoconductor drum 1 can be cleaned by the cleaning member 41,
supported by the biasing device 42 of the cleaning unit 4. The
cleaning member 41 may have a blade shape, for example. In FIG. 3,
the cleaning member 41 is angled and contacted to the
photoconductor drum 1 in a counter direction. Although the blade
24a of the layer adjusting unit 24 is angled and contacted to the
photoconductor drum 1 in a trailing direction, the blade 24a can be
angled and contacted to the photoconductor drum 1 in a counter
direction.
[0180] After the photoconductor surface is cleaned by the cleaning
unit 4, new protective agent is supplied to the photoconductor
surface by the agent applicator 22, and the protective agent is
extended on photoconductor surface as a thin protective layer by
the blade 24a of the layer adjusting unit 24. The protective agent
used in an exemplary embodiment can be absorbed well to a higher
hydrophilic portion of the photoconductor surface, wherein the
hydrophilic portion is caused by electrical stress. Accordingly,
even if the photoconductor surface is partially degraded by greater
electrical stress, which may occur temporarily, degradation of the
photoconductor can be reduced or lessened by absorption of the
protective agent on the photoconductor.
[0181] After the charge roller 3 charges the photoconductor drum 1
supplied with a protective layer, an optical writing unit (not
shown) irradiates a laser beam L to the photoconductor drum 1 to
form a latent image on the photoconductor drum 1, and then the
latent image is developed by toner supplied by the development unit
5 as a toner image, which is transferred to the intermediate
transfer member 7 by using the transfer roller 6.
[0182] In an exemplary embodiment, the process cartridge 10
includes a charging unit using corona discharge, scorotron
charging, or a charge roller. From a viewpoint of reducing a size
of apparatus and oxidizing gas generation, such as ozone, a charge
roller is preferably used. The charge roller 3 may contact the
photoconductor drum 1 or may be disposed opposite to the
photoconductor drum 1 across a gap, such as 20 .mu.m to 100 .mu.m.
Such charge roller 3, supplied with a given voltage, charges the
photoconductor drum 1. The charge roller 3 charges the
photoconductor drum 1 with a direct-current voltage (referred as DC
charging), or a superimposed voltage superimposing a given
alternating voltage to a direct-current voltage (referred as AC
charging), for example. In the AC charging method, electric
discharges are repeatedly occurred between the photoconductor drum
1 and the charge roller 3 for thousands of times per second, and
thereby the photoconductor drum 1 may receive damages during a
charging process. In view of such damages, a protective agent may
be constantly applied to the photoconductor drum 1 to protect the
photoconductor drum 1 from an effect of the AC charging because the
protective agent may be degraded or decomposed during a charging
process.
[0183] The charge roller 3 may be preferably configured with a
conductive supporter, a polymer layer, and a surface layer. The
conductive supporter, used as a supporter and an electrode of the
charge roller 3, is made of a conductive material, such as metal or
metal alloy (e.g., aluminum, cupper alloy, stainless steel), metal
(e.g., iron) coated with chrome or nickel, or resin added with a
conductive material, for example.
[0184] The polymer layer may be a conductive layer having a given
resistance, such as from 10.sup.6 .OMEGA.cm to 10.sup.9 .OMEGA.cm,
in which a conductive agent is added in a polymeric material to
adjust a resistance. Such polymeric material may be thermoplastic
elastomer, such as polyester, polyolefin; thermoplastic resin
having styrene, such as polystyrene, copolymer of
styrene/butadiene, copolymer of styrene/acrylonitrile, copolymer of
styrene/butadiene/acrylonitrile; rubber material, such as isoprene
rubber, chloroprene rubber, epichloro hydrin rubber, butyl rubber,
urethane rubber, silicone rubber, fluorocarbon rubber,
styrene/butadiene rubber, butadiene rubber, nitrile rubber,
ethylene-propylene rubber, epichlorohydrin/ethyleneoxide copolymer
rubber, epichlorohydrin/ethyleneoxide/allylglycidyl ether copolymer
rubber, ethylene/propylene/dien copolymer rubber(EPDM),
acrylonitrile/butadiene copolymer rubber, natural rubber, and
rubber mixing these rubber materials. Among the rubber materials,
silicone rubber, ethylene/propylene rubber,
epichlorohydrin/ethyleneoxide copolymer rubber,
epichlorohydrin/ethyleneoxide/allylglycidyl ether copolymer rubber,
acrylonitrile/butadiene copolymer rubber, and rubber mixing these
rubber materials are preferably used. Such rubber materials may be
foamed rubber or unfoamed rubber.
[0185] The conductive agent may be an electronic conductive agent,
or an ion conductive agent, for example. The electronic conductive
agent may be fine powders of carbon black, such as ketjen black,
acetylene black; thermal decomposed carbon, graphite; conductive
metal or alloy, such as aluminum, cupper, nickel, stainless steel;
conductive metal oxide, such as tin oxide, indium oxide, titanium
oxide, tin oxide/antimony oxide solid solution, tin oxide/indium
oxide solid solution; and surface-treated insulation material
having conductivity, for example. The ion conductive agent may be
perchlorate or chlorate of tetraethyl ammonium or lauryl trimethyl
ammonium; and perchlorate or chlorate of alkali metal or
alkaline-earth metal, such as lithium, magnesium, for example. Such
conductive agents may be used alone or in combination.
[0186] Although such conductive agents may be added to a polymeric
material with a given amount, the electronic conductive agent is
added to a 100 weight part of polymeric material for a range of 1
to 30 weight part, and more preferably a range of 15 to 25 weight
part, and the ion conductive agent is added to a 100 weight part of
polymeric material for a range of 0.1 to 5.0 weight part, and more
preferably a range of 0.5 to 3.0 weight part.
[0187] The surface layer of the charge roller 3, composed of
polymeric material, may have a dynamic ultra-micro hardness of from
0.04 to 0.5, for example. Such polymeric material may be polyamide,
polyurethane, polyvinylidene fluoride, copolymer of ethylene
tetrafluoride, polyester, polyimide, silicone resin, acrylic resin,
polyvinyl butyral, copolymer of ethylene tetrafluoroethylene,
melamine resin, fluorocarbon rubber, epoxy resin, polycarbonate,
polyvinyl alcohol, cellulose, polyvinylidene chloride, polyvinyl
chloride, polyethylene, copolymer of ethylene vinyl acetate, or the
like, for example. From a viewpoint of separation performance with
toner, polyamide, polyvinylidene fluoride, copolymer of ethylene
tetrafluoride, polyester, and polyimide are preferably used. Such
polymeric materials can be used alone or in combination. Such
polymeric material has a number average molecular weight,
preferably in a range of 1,000 to 100,000, and more preferably in a
range of 10,000 to 50,000, for example.
[0188] The surface layer is formed by mixing the polymeric
material, the conductive agent, and fine powders. The fine powders
may be metal oxide or complex metal oxide, such as silicon oxide,
aluminum oxide, barium titanate, or polymer powder of
tetrafluoroethylene, vinylidene fluoride, for example, but not
limited thereto. Such fine powders can be used alone or in
combination.
[0189] A description is given to a development unit used in a
process cartridge according to an exemplary embodiment with
reference to FIG. 10. The process cartridge 10 includes a
development unit to develop a latent image formed on the
photoconductor drum 1 as a toner image using a developing agent.
Such developing agent may be one-component developing agent not
having carrier, and two-component developing agent having toner and
carrier. As shown in FIG. 10, the development unit 5 includes the
developing roller 51 used as a developing agent carrier, partially
exposed to the photoconductor drum 1 through an opening of a casing
of the development unit 5.
[0190] Toner particles supplied to the development unit 5 from a
toner bottle (not shown) are agitated with carrier particles and
transported by the agitation transport screws 52 and 53, and then
carried on the developing roller 51, which includes a magnet roller
and a developing sleeve, wherein the magnet roller generates a
magnetic field, and the developing sleeve coaxially rotates around
the magnet roller. Chains of carrier particles of the developing
agent accumulate on the developing roller 51 with an effect of
magnetic force of the magnet roller, and then transported to a
developing section facing the photoconductor drum 1. The developing
roller 51 may rotate at a linear velocity greater than a linear
velocity of the photoconductor drum 1 at the developing section,
for example. Chains of carrier particles accumulated on the
developing roller 51 contact a surface of the photoconductor drum
1, and supply toner particles adhered on the carrier surface to the
surface of the photoconductor drum 1. At this time, the developing
roller 51 is supplied with a developing bias from a power source
(not shown) to form a developing electric field at the developing
section. In such developing electric field, toner particles move
from the developing roller 51 to a latent image on the
photoconductor drum 1, and adhere the latent image. Such toner
adhesion to the latent image of the photoconductor drum 1 generates
a toner image of each color.
[0191] A description is now given to an image forming apparatus
according to an exemplary embodiment with reference to FIG. 11.
FIG. 11 illustrates a schematic cross-sectional view of an image
forming apparatus 100 employing the protective layer setting unit 2
according to an exemplary embodiment. The image forming apparatus
100 includes an image forming unit 110, a scanner 120, an automatic
document feeder (ADF) 130, and a sheet feed unit 200, for example.
The image forming unit 110 conducts an image forming. The scanner
120 is disposed over the image forming unit 110, and the ADF 130 is
disposed over the scanner 120. The sheet feed unit 200 is disposed
under the image forming unit 110. The image forming apparatus 100
may have and communication function with an external device, such
as personal computer or the like, in which the image forming
apparatus 100 can be used as a printer or a scanner. The image
forming apparatus 100 may also have a facsimile function, in which
the image forming apparatus 100 can be used as a facsimile by
connecting the image forming apparatus 100 with a telephone line or
optical fiber line.
[0192] The image forming unit 110 includes four image forming
engines 10 having a similar configuration one another except colors
of toner used in the development unit 5. Each of the image forming
engines 10 respective toner color image, such as yellow(Y),
magenta(M), cyan(C), black(K) color image, and such toner images
are transferred to a transfer sheet or an intermediate transfer
member to form a full color image. In FIG. 11, the image forming
engines 10 are tandemly arranged over the intermediate transfer
member 7, extended by rollers, in which the toner images formed by
the image forming engines 10 are transferred to the intermediate
transfer member 7, and then transferred to a transfer sheet using a
secondary transfer unit 12.
[0193] The image forming engine 10 has a configuration similar to a
configuration shown in FIG. 10, wherein photoconductor drum 1 is
surrounded by the protective layer setting unit 2, the charge
roller 3, the optical writing unit 8, the development unit 5, the
transfer roller 6, and the cleaning unit 4. The image forming
engine 10 may be used as the process cartridge 10 as similar to
FIG. 10. Such process cartridge 10 is detachably mountable to the
image forming unit 110.
[0194] A description is now given to an image forming apparatus
according to an exemplary embodiment with reference to FIG. 11.
Hereinafter, an image forming process using negative/positive
process is described.
[0195] The photoconductor drum 1 may be an OPC (organic
photoconductor) having an organic photoconductive layer, which is
de-charged by a decharging lamp (not shown) to prepare for an image
forming operation. Such photoconductor drum 1 is uniformly charged
to a negative charge by the charge roller 3. Such charge unit 3 is
applied with a given voltage, such as direct current voltage
superimposed with alternating-voltage, from a voltage power source
(not shown), in which such given voltage is used to charge the
photoconductor drum 1 to a given potential.
[0196] The charged photoconductor drum 1 is then irradiated with a
laser beam emitted from the optical writing unit 8 to form a latent
image on the charged photoconductor drum 1, in which an absolute
potential value of light-exposed portion becomes smaller than an
absolute potential value of non-exposed portion. The laser beam,
emitted by a laser diode, is reflected by a polygon mirror rotating
at a high speed, and then scanned on the surface of the
photoconductor drum 1 in an axial direction of the photoconductor
drum 1.
[0197] Such formed latent image is then developed by a developing
agent, supplied from a developing sleeve of the development unit 5,
as a visible toner image. The developing agent may be toner-only
component or a mixture of toner particles and carrier particles.
When developing the latent image, a voltage power source (not
shown) may supply a given developing bias voltage to the developing
sleeve, wherein such developing bias voltage may be direct-current
voltage or a voltage having direct-current voltage superimposed
with alternating-current voltage having a voltage value, set
between a potential of light-exposed portion and a potential of
non-exposed portion of the photoconductor drum 1, for example.
[0198] The toner images formed on the photoconductor drum 1 are
transferred to the intermediate transfer member 7 by the transfer
roller 6, and such toner image is then transferred to a transfer
medium such as a paper fed from the sheet feed unit 200. The sheet
feed unit 200 has sheet cassettes 201a, 201b, 201c, 201d, a feed
roller 202, a separation roller 203, transport rollers 204, 205,
206, and a registration roller 207. A transfer sheet is fed by the
feed roller 202 and the separation roller 203 from one of the sheet
cassettes 201 to the registration roller 207 via the transport
rollers 204, 205, 206 at a given timing synchronized to a timing of
image forming, such as primary transfer timing. Then, the
registration roller 207 feed the transfer sheet to a secondary
transfer nip. At the secondary transfer nip, the secondary transfer
unit 12 transfers the toner images from the intermediate transfer
member 7 to the transfer sheet. In such transfer process, the
transfer roller 6 and the secondary transfer unit 12 are preferably
supplied with a transfer bias voltage having a polarity opposite to
a polarity of toner particles. Toner particles remaining on the
photoconductor drum 1 are removed by the cleaning member 41, and
then recovered in a toner recovery section in the cleaning unit 4.
Toner particles remaining on the intermediate transfer member 7 are
removed by a cleaning member of a belt cleaning unit 9, and then
recovered in a toner recovery section in the belt cleaning unit
9.
[0199] The image forming apparatus 100 may have a plurality of the
image forming engines 10 arranged in tandem along the intermediate
transfer member 7. The plurality of image forming engines 10, form
different toner color images, and sequentially transfer the toner
color images to the intermediate transfer member 7, and then the
toner color images are transferred to a transfer medium. Then, a
transport unit 13 transports the transfer medium to a fixing unit
14 to fix toner images on the transfer medium by applying heat.
After the fixing process, the transfer medium is ejected to a tray
17 by a transport unit 15 and an ejection roller 16. Further, the
image forming apparatus 100 can print images on both face of a
transfer medium. When printing images on both face, a transport
route after the fixing unit 14 is switched to transport the
transfer medium to an inverting unit 210 to invert the faces of the
transfer medium, and then the transfer medium is fed to the
secondary transfer nip by the transport roller 206 and the
registration roller 207 to form an image on back face the transfer
medium. Then, the transport unit 13 transports the transfer medium
to the fixing unit 14 to fix toner images on the transfer medium,
and the transfer medium is ejected to the tray 17.
[0200] Alternatively, toner color images can be transferred from
the photoconductor drums 1Y, 1M, 1C, and 1K of the image forming
engines 10 using a direct transfer method. Specifically, a
transport belt is used instead of the intermediate transfer member
7, and toner color images are transferred from the photoconductor
drums 1Y, 1M, 1C, and 1K to a transfer medium transported by the
transport belt, and then the toner images is fixed on the transfer
medium by a fixing unit.
[0201] In the image forming apparatus 100, the charge roller 3
preferably contacts the photoconductor drum 1 or is preferably
disposed opposite to the photoconductor drum 1 across a tiny gap.
Such charge roller 3 can preferably reduce oxidizing gas
generation, such as ozone, compared to a corona discharge unit,
such as corotron, scorotron charging using wire for discharge
during a charging process. However, because electrical discharge
occurs proximity to the photoconductor surface when such charge
roller 3 is used, the photoconductor drum 1 receives greater
electrical stress. In an exemplary embodiment, the protective layer
setting unit 2 is used to apply a protective agent to the
photoconductor drum 1, by which the photoconductor drum 1 can be
protected from such electrical stress effectively and a degradation
of the photoconductor drum 1 can be reduced or lessened over time.
Accordingly, the image forming apparatus 100 can produce higher
quality images over time while reducing variation of image quality
caused by environmental condition or the like.
[0202] A description is now given to a photoconductor preferably
used in an exemplary embodiment. The photoconductor used in an
image forming apparatus is composed of a conductive support and a
photosensitive layer provided thereon.
[0203] The photosensitive layer may be of a monolayer type in which
a charge generation material and a charge transport material are
mixed, or a forward lamination type in which a charge transport
layer is provided on a charge generation layer, or a reverse
lamination type in which a charge generation layer is provided on a
charge transport layer. Further, a surface protective layer may be
provided on the photosensitive layer to enhance physical strength,
anti-abrasiveness, anti-gas property, cleaning performance and the
like of the photoconductor. Further, a backing layer may be
provided between the photosensitive layer and the conductive
support. Further, each layer may be added with an appropriate
amount of plasticizer, antioxidant, leveling agent and the like as
required.
[0204] The conductive support of the photoconductor may have a drum
shape prepared as below, for example. A cylindrically shaped
plastic/paper is covered with a metal compound by vapor deposition
or spattering to form the conductive support. The metal compound
may be aluminum, nickel, chromium, nichrome, copper, gold, silver,
or platinum, or metal oxide, such as tin oxide or indium oxide,
having conductivity of volume resistance of equal to or less than
10.sup.10 .OMEGA.cm. Alternatively, a metal plate, such as
aluminum, aluminum alloy, nickel, stainless, or a tube obtained by
extruding or drawing the metal plate, is subjected to surface
treatment such as grinding, super-finishing, polishing and the like
to form the conductive support. As the drum-like support, those
having a diameter ranging from 20 mm to 150 mm, preferably from 24
mm to 100 mm, more preferably from 28 mm to 70 mm can be used.
Diameter of drum-like support of equal to or less than 20 mm is not
preferable because arrangement of a charging device, a light
exposure device, a development device, a transfer device, and a
cleaning device around the drum is physically difficult, and
diameter of drum-like support of equal to or more than 150 mm is
not preferable because the size of image forming apparatus
increases. When the image forming apparatus is of tandem type, in
particular, the diameter is equal to or less than 70 mm, and
preferably equal to or less than 60 mm because a plurality of
photoconductors should be disposed. Also known conductive endless
belts, such as nickel belt or stainless belt, may be used as a
conductive support.
[0205] The backing layer of photoconductor for use in an exemplary
embodiment may be a resin layer, a resin layer having white
pigment, or a metal oxide layer obtainable by chemically or
electrochemically oxidizing surface of conductive base, for
example, and the resin layer having white pigment is preferred.
Examples of the white pigment include metal oxide, such as titanium
oxide, aluminum oxide, zirconium oxide, and zinc oxide, and among
these, it is preferred to contain titanium oxide having excellent
ability to prevent charges from being injected from the conductive
base. Examples of the resin used in the backing layer include
thermoplastic resin, such as polyamide, polyvinyl alcohol, casein,
methyl cellulose; thermosetting resin, such as acryl, phenol,
melamine, alkyd, unsaturated polyester, epoxy; and these may be
used singly or in combination.
[0206] Examples of the charge generation material of photoconductor
for use in an exemplary embodiment include organic pigments and
dyes, such as azo pigments (e.g., monoazo pigments, bisazo
pigments, trisazo pigments, tetrakisazo pigments), triarylmethane
dyes, thiazine dyes, oxazine dyes, xanthene dyes, cyanine
dyestuffs, styryl dyestuffs, pyrylium dyes, quinacridone dyes,
indigo dyes, perylene pigments, polycyclic quinone pigments,
bisbenzimidazole pigments, indathrone pigments, squarylium
pigments, phthalocyanine pigments; and inorganic materials, such as
serene, serene-arsenic, serene-tellurium, cadmium sulfide, zinc
oxide, titanium oxide and amorphous silicon, and the charge
generation material may be used singly or in combination of plural
kinds. The backing layer of photoconductor may be composed of one
layer or a plurality of layers.
[0207] Examples of the charge transport material of photoconductor
for use in an exemplary embodiment include anthracene derivatives,
pyrene derivatives, carbazole derivatives, tetrazole derivatives,
metallocene derivatives, phenothiazine derivatives, pyrazoline
compounds, hydrazone compounds, styryl compounds, styryl hydrazone
compounds, enamine compounds, butadiene compounds, distyryl
compounds, oxazole compounds, oxadiazole compounds, thiazole
compounds, imidazole compounds, triphenylamine derivatives,
phenylenediamine derivatives, aminostilbene derivatives, and
triphenylmethane derivatives, and these may be used singly or in
combination.
[0208] The binding resin used for forming the photosensitive layer
of charge generation layer and charge transport layer include known
thermoplastic resins, thermosetting resins, photosetting resins,
and photoconductive resins having electric insulation. Examples of
binding resin include thermoplastic resin, such as polyvinyl
chloride, polyvinylidene chloride, vinyl chloride-vinyl acetate
copolymer, vinyl chloride-vinyl acetate-maleic anhydride copolymdr,
ethylene-vinyl acetate copolymer, polyvinyl butyral, polyvinyl
acetal, polyester, phenoxy resin, (meth)acryl resin, polystyrene,
polycarbonate, polyacrylate, polysulfone, polyethersulfone and ABS
resin; thermosetting resin, such as phenol resin, epoxy resin,
urethane resin, melamine resin, isocyanate resin, alkyd resin,
silicone resin; thermosetting resin, such as thermosetting acryl
resin; and photoconductive resin, such as polyvinyl carbazole,
polyvinyl anthracene, polyvinylpyrene. These can be used alone or a
mixture of plural kinds of binding resins can be used, but are not
limited thereto. However, if the charge generation layer or charge
transport layer is used as a top surface layer, the binding resin
may use polycarbonate resin having a transparency to a light beam
used for writing an image and a good level of insulation
performance, physical strength, and adhesiveness.
[0209] As the antioxidant, those listed below may be used, for
example.
[0210] Monophenol compound: 2,6-di-t-butyl-p-cresol, butylated
hydroxy anisole, 2,6-di-t-butyl-4-ethylphenol,
stearyl-.beta.-(3,5-di-t-butyl-4-hydroxyphenyl)propionate,
3-t-butyl-4-hydroxyanisole or the like.
[0211] Bisphenol compound:
2,2'-methylene-biS-(4-methyl-6-t-butylphenol),
2,2'-methylene-bis-(4-ethyl-6-t-butylphenol),
4,4'-thiobis-(3-methyl-6-t-butylphenol),
4,4'-butylidenebis-(3-methyl-6-t-butylphenol) or the like.
[0212] Polymeric phenol compound:
1,1,3-tris-(2-methyl-4-hydroxy-5-t-butylphenyl)butane,
1,3,5-trimethyl-2,4,6-tris(3,5-di-t-butyl-4-hydroxybenzyl)benzene,
tetrakis-[methylene-3-(3',5'-di-t-butyl-4'-hydroxyphenyl)propionate]metha-
ne, bis[3,3'-bis(4'-hydroxy-3'-t-butylphenyl)butylic acid]glycol
ester, tocopherols, or the like.
[0213] p-phenylenediamine: N-phenyl-N'-isopropyl-p-phenylene
diamine, N,N'-di-sec-butyl-p-phenylenediamine,
N-phenyl-N-sec-butyl-p-phenylenediamine,
N,N'-di-isopropyl-p-phenylenediamine,
N,N'-dimethyl-N,N'-di-t-butyl-p-phenylenediamine, or the like.
[0214] Hydroquinone: 2,5-di-t-octylhydroquinone,
2,6-didodecylhydroquinone, 2-dodecylhydroquinone,
2-dodecyl-5-chlorohydroquinone, 2-t-octyl-5-methylhydroquinone,
2-(2-octadecenyl)-5-methylhydroquinone or the like.
[0215] Organic sulfur compound: Dilauryl-3,3'-thiodipropionate,
distearyl-3,3'-thiodipropionate,
ditetradecyl-3,3'-thiodipropionate, or the like.
[0216] Organic phosphor compound: Triphenyl phosphine,
tri(nonylphenyl)phosphine, tri(dinonylphenyl)phosphine, tricresyl
phosphine, tri(2,4-dibutylphenoxy)phosphine, or the like.
[0217] As the plasticizer, resin, such as dibutylphthalate and
dioctylphthalate that is commonly used as a plasticizer, may be
used, and an appropriate use amount is about 0 to 30 parts by
weight, relative to 100 parts by weight of the binding resin.
[0218] Further, a leveling agent may be added to the charge
transport layer. As the leveling agent, silicone oil, such as
dimethyl silicone oil, methylphenyl silicone oil, and polymer or
oligomer having perfluoroalkyl group as a side chain can be used,
for example, and an appropriate use amount is about 0 to 1 part by
weight, relative to 100 parts by weight of binding resin.
[0219] The surface layer of photoconductor is provided for
improving or enhancing physical strength, abrasion resistance (or
anti-abrasiveness), gas resistance (or anti-gas property),
cleanability (or cleaning performance) of a photoconductor. As the
surface layer, those of polymer having higher physical strength
than the photosensitive layer, and those of polymer in which
inorganic fillers are dispersed can be exemplified. The polymer
used for the surface layer may be any polymers including
thermoplastic polymers and thermosetting polymers, and
thermosetting polymers are particularly preferred because they have
high physical strength and a good ability of reducing abrasion,
which may occur when frictioned with a cleaning blade. The surface
layer may not need to have charge transport ability insofar as it
has a smaller film thickness. However, when a thicker surface layer
not having charge transport ability is formed, a photoconductor may
decrease its photosensitivity, increase its post-exposure
potential, and increase its residual potential. Therefore, it is
preferred to contain the charge transport material in the surface
layer or to use polymer having charge transport ability for the
surface layer. In general, the photosensitive layer and the surface
layer have physical strength, which are greatly different each
other. When the surface layer is abraded and disappeared due to
friction with a cleaning blade, the photosensitive layer will be
also abraded in soon. Therefore, when providing a surface layer,
the surface layer has a sufficient film thickness, ranging from 0.1
.mu.m to 12 .mu.m, preferably ranging from 1 .mu.m to 10 .mu.m, and
more preferably from 2 .mu.m to 8 .mu.m. Film thickness of surface
layer of equal to or less than 0.1 .mu.m is not preferred because
it is so thin that partial disappearance is likely to occur due to
friction with a cleaning blade, and abrasion of photosensitive
layer proceeds from the disappeared part. Film thickness of surface
layer of equal to or more than 12 .mu.m is not preferred because
such thicker surface layer may decrease photosensitivity, increase
post-exposure potential, and increase residual potential for a
photoconductor, and if polymer having charge transport ability and
relatively high price is used for surface layer, a cost of
photoconductor becomes higher, which is not preferable.
[0220] As the polymer used in the surface layer of the
photoconductor, polycarbonate resin having transparency to a light
beam at the time of an image writing, excellent insulation,
physical strength, and adhesiveness is preferred.
[0221] To enhance a physical strength of a surface layer, the
surface layer may be dispersed with fine powders of metal
component, metal oxide, or the like. Examples of the metal oxide
include tin oxide, potassium titanate, titanium oxide, zinc oxide,
indium oxide, and antimony oxide, or titanium nitride. Further, to
enhance an anti-abrasiveness of a surface layer, the surface layer
may be added with fluorocarbon resin, such as
polytetrafluoroethylene, silicone resin, or compounds of these
resins having dispersed inorganic materials, for example.
[0222] In an exemplary embodiment, photoconductor drums and an
intermediate transfer member are used as image carrying member, in
which toner images formed on photoconductors are transferred to the
intermediate transfer member, and then the toner images are
transferred to a transfer medium.
[0223] The intermediate transfer member may be preferably made of a
conductive material having a volume resistance from 10.sup.5
.OMEGA.cm to 10.sup.11 .OMEGA.cm, and a surface resistance from
5.times.10.sup.10 .OMEGA./.quadrature. to 5.times.10.sup.11
.OMEGA./.quadrature., for example. If the surface resistance is
less than 5.times.10.sup.10 .OMEGA./.quadrature., toner scattering
may occur when a discharge is conducted for transferring a toner
image from the photoconductor to the intermediate transfer member,
by which toner image may be disturbed. If the surface resistance is
greater than 5.times.10.sup.11 .OMEGA./.quadrature., electric
charge corresponding to a toner image may remain on the
intermediate 5 transfer member after transferring the toner image
from the intermediate transfer member to a transfer medium, such as
paper, by which such remained electric charge may unpreferably
appear as an image during a subsequent image forming operation.
[0224] The intermediate transfer member may be made from a
conductive material and thermoplastic resin, in which such
materials are kneaded, extruded, and formed into a belt shape or a
cylindrical shape. The conductive material may be metal oxide, such
as tin oxide, indium oxide, conductive particle, such as carbon
black, or conductive polymer. These may be used alone or in
combination. Alternatively, such conductive material can be added
in resin solution having monomer oligomer used for cross-linking
reaction, and then a centrifugal molding is conducted while
applying heat to form an endless belt.
[0225] If the intermediate transfer member is provided with a
surface layer, the surface layer of the intermediate transfer
member may include materials used for the surface layer of
photoconductor surface except the charge transport material, and a
conductive material to adjust resistance.
[0226] A description is now given to toner for use in an exemplary
embodiment. The toner preferably has an average circularity of from
0.93 to 1.00. In an exemplary embodiment, an average value obtained
by the following (Equation 2) is defined as circularity of toner
particles. The average circularity is an index of the degree of
irregularities of toner particles. If the toner has a perfect
sphericity, the average circularity takes a value of 1.00. The more
irregularities of surface profile, the smaller the average
circularity.
Circularity SR=(circumferential length of a circle having an area
equivalent to a projected area of a particle)/(circumferential
length of a projected image of the particle) (Equation 2)
[0227] If the average circularity is in a range of 0.93 to 1.00,
toner particles may have smooth surface, and thereby toner
particles contact with each other at a small contact area, and
toner particles and the photoconductor drum 1 also contact with
each other at a small contact area, by which such toner particles
can have an excellent transfer performance. Further, because such
toner particles have no corners, an agitation torque for the
developing agent in the developing unit 3 can be set smaller, and
thereby the agitation can be conducted in a stable manner, by which
defective images may not occur.
[0228] Further, because such toner particles have no corners, a
pressure, applied to toner particles when transferring a toner
image to a transfer member or a recording member, can be uniformly
applied to the toner particles used for forming dot images.
Accordingly, a void may not occur on a transferred image. Further,
because such toner particles have no corners, the toner particles
may not have grinding force so much, by which such toner particles
may not damage or wear the surface of the photoconductor drum
1.
[0229] A description is given to a method of measuring circularity
of toner particles. The degree of circularity SR of particles can
be measured by using a flow-type particle image analyzing apparatus
FPIA-1000 produced by Toa Medical Electronics Co., Ltd. Such
measuring may be conducted as below.
[0230] First, 0.1-0.5 ml of surfactant, preferably alkyl benzene
sulfonate, as a dispersing agent is added to 100-150 ml of water in
a container from which impurities have been removed in advance, and
about 0.1-0.5 g of measurement sample is further added thereto.
Then, an ultrasonic wave is applied to a suspension having a sample
dispersed therein for 1 to 3 minute to set a suspension dispersion
density as 3,000-10,000 particles/ul, and the shape of a toner
particles and distribution of the degree of circularity of toner
particles are measured by using the above-mentioned flow-type
particle image measuring apparatus.
[0231] A weight-average particle diameter D4 of toner particles is
preferably from 3 .mu.m to 10 .mu.m, for example. In this range,
the toner particles may have a diameter, which is a sufficiently
small size for developing fine dots of latent image. Accordingly,
such toner particles may have good reproducibility of image dots.
If the weight-average particle diameter D4 is too small, a
phenomenon such as lower transfer efficiency and lower blade
cleaning performance may be more likely to occur. If the
weight-average particle diameter D4 is too great, toner for forming
characters and lines may unfavorably spatter.
[0232] Further, the toner particles preferably have a ratio (D4/D1)
of from 1.00 to 1.40, wherein the D4/D1 is a ratio of the
weight-average particle diameter D4 and the number-average particle
diameter D1. The closer the ratio (D4/D1) is 1, the sharper the
toner size distribution of the toner particles. If the (D4/D1) is
in a range of 1.00 to 1.40, an latent image can be developed by any
toner particles having different particle diameters but set in such
D4/D1 ratio, by which an image having higher quality can be
produced. Further, because the toner particles have a sharper size
distribution, a tribo electrically-charging profile of toner
particles becomes also sharp, by which fogging can be reduced.
Further, if toner particles have uniform diameter, the toner
particles can be developed on a latent image dot in a precise array
manner, and thereby dot reproducibility by toner particles becomes
excellent.
[0233] The weight average particle diameter (D4), number average
particle diameter (D1), and particle diameter distribution of a
toner can be measured using an instrument COULTER COUNTER TA-II or
COULETR MULTISIZER II from Coulter Electrons Inc. The typical
measuring method is as follows:
[0234] (1) 0.1 to 5 ml of a surfactant (preferably alkylbenzene
sulfonate) is included as a dispersant in 100 to 150 ml of an
electrolyte (i.e., 1% NaCl aqueous solution including a first grade
sodium chloride such as ISOTON-II from Coulter Electrons Inc.);
[0235] (2) 2 to 20 mg of a toner is added to the electrolyte and
dispersed using an ultrasonic dispersing machine for about 1 to 3
minutes to prepare a toner suspension liquid;
[0236] (3) the volume and the number of toner particles are
measured by the above instrument using an aperture of 100 .mu.m to
determine volume and number distribution thereof; and
[0237] (4) the weight average particle diameter (D4) and the number
average particle diameter (D1) are determined.
[0238] The channels include 13 channels as follows: from 2.00 to
less than 2.52 .mu.m; from 2.52 to less than 3.17 .mu.m; from 3.17
to less than 4.00 .mu.m; from 4.00 to less than 5.04 .mu.m; from
5.04 to less than 6.35 .mu.m; from 6.35 to less than 8.00 .mu.m;
from 8.00 to less than 10.08 .mu.m; from 10.08 to less than 12.70
.mu.m; from 12.70 to less than 16.00 .mu.m; from 16.00 to less than
20.20 .mu.m; from 20.20 to less than 25.40 .mu.m; from 25.40 to
less than 32.00 .mu.m; and from 32.00 to less than 40.30 .mu.m.
Namely, particles having a particle diameter of from not less than
2.00 .mu.m to less than 40.30 .mu.m can be measured.
[0239] Such substantially spherically shaped toner particles can be
prepared by a cross-linking reaction and/or an elongation reaction
of toner composition in an aqueous medium in the presence of fine
resin particles. Specifically, the toner composition includes a
polyester prepolymer having a functional group containing nitrogen
atom, a polyester, a colorant, and a release agent, for example.
The surface of toner particles prepared by such method can be
hardened, by which hot offset can be reduced, and thereby a
contamination of a fixing unit by toner particles can be reduced.
Accordingly, an occurrence of defective images can be reduced.
[0240] A prepolymer formed as modified polyester resin may be
polyester prepolymer (a) having isocyanate group, and amine (b) may
be elongated or cross-linked with the polyester prepolymer (a).
[0241] The polyester prepolymer (a) having isocyanate group may be
a reaction product of polyester with polyisocyanate (3), in which
the polyester is a polycondensation product of polyol (1) and
polycarboxylic acid (2) and having an active hydrogen group. The
active hydrogen group of the polyester may be hydroxyl group (e.g.,
alcoholic hydroxyl group, phenolic hydroxyl group), amino group,
carboxyl group, and mercapto group, for example. Among these,
alcoholic hydroxyl group is preferred.
[0242] Examples of the polyol (1) include diol (1-1) and tirvalent
or more polyol (1-2), and (1-1) alone or a mixture of (1-1) and
small amount of (1-2) is preferably used.
[0243] Examples of the diol (1-1) include alkylene glycol (e.g.,
ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol,
1,4-butane diol, 1,6-hexane diol); alkylene ether glycol (e.g.,
diethylene glycol, triethylene glycol, dipropylene glycol,
polyethylene glycol, polypropylene glycol, polytetramethylene ether
glycol); alicyclic diol (e.g., 1,4-cyclohexane dimethanol,
hydrogenated bisphenol A); bisphenol(e.g., bisphenol A, bisphenol
F, bisphenol S); adduct of alkylene oxide of the alicyclic diol
(e.g., ethylene oxide, propylene oxide, butylene oxide); and adduct
of alkylene oxide of the bisphenol (e.g., ethylene oxide, propylene
oxide, butylene oxide). Among these, alkylene glycol having a
carbon number of 2 to 12 and adduct of the alkylene oxide of the
bisphenol are preferable. Particularly preferable are the adduct of
the alkylene oxide of the bisphenol, and a combination of an adduct
of the alkylene oxide of the bisphenol and alkylene glycol having a
carbon number of 2 to 12.
[0244] Examples of the tirvalent or more polyol (1-2) include
trihydric to otcahydric alcohols and polyvalent aliphatic alcohol
(e.g., glycerin, trimethylolethane, trimethylolpropane,
pentaerythritol, sorbitol); tirvalent or more phenol (e.g.,
trisphenol PA, phenol borax, cresol novolac); and adduct of
alkylene oxide of the tirvalent or more polyphenol.
[0245] Examples of the polycarboxylic acid (2) include dicarboxylic
acid (2-1) and a tirvalent or more polycarboxylic acid (2-2), and
(2-1) alone or a mixture of (2-1) and a small amount of (2-2) are
preferably used. Examples of the dicarboxylic acid (2-1) include
alkylene dicarboxylic acid (e.g., succinic acid, adipic acid,
sebacic acid); alkenylene dicarboxylic acid (e.g., maleic acid,
fumaric acid); and aromatic dicarboxylic acid (e.g., phthalic acid,
isophthalic acid, terephthalic acid, naphthalen dicarboxylic acid).
Among these, alkenylene dicarboxylic acid having a carbon number of
4 to 20 or aromatic dicarboxylic acid having a carbon number of 8
to 20 are preferable. Examples of the tirvalent or more
polycarboxylic acid (2-2) include aromatic polycarboxylic acid
having a carbon number of 9 to 20 (e.g., trimellitic acid,
pyromellitic acid). Acid anhydrides or lower alkyl ester (e.g.,
methyl ester, ethyl ester, isopropyl ester) of the polycarboxylic
acid (2) may be reacted with polyol (1).
[0246] A ratio of the polyol (1) and the polycarboxylic acid (2) is
preferably from 2/1 to 1/1, more preferably from 1.5/1 to 1/1, and
further preferably from 1.3/1 to 1.02/1 as an equivalent ratio of
[OH]/[COOH] between hydroxyl group [OH] and carboxyl group
[COOH].
[0247] Examples of the polyisocyanate (3) include aliphatic
polyisocyanate (e.g., tetramethylene diisocyanate, hexamethylene
diisocyanate, 2,6-diisocyanate methyl caproate); alicyclic
polyisocyanate (e.g., isophorone diisocyanate, cyclohexylmethane
diisocyanate); aromatic diisocyanate (e.g., tolylene diisocyanate,
diphenylmethane diisocyanate); aromatic aliphatic diisocyanate
(e.g., .alpha.,.alpha.,.alpha.',.alpha.'-tetramethylxylylene
diisocyanate); isocyanates; and compounds formed by blocking the
polyisocyanate phenol derivative, oxime, or caprolactam. These can
be used alone or in combination.
[0248] A ratio of the polyisocyanate (3) is preferably from 5/1 to
1/1, more preferably from 4/1 to 1.2/1, and further preferably from
2.5/1 to 1.5/1 as an as an equivalent ratio of [NCO]/[OH] between
isocyanate group [NCO] and hydroxyl group [OH] of polyester having
hydroxyl group. If the [NCO]/[OH] becomes too great,
low-temperature fixability of the toner may deteriorate. For
example, if the molar ratio of [NCO] becomes less than 1, the urea
content in modified polyester becomes lower, by which hot offset
resistance may be degraded.
[0249] The content of polyisocyanate (3) in the prepolymer (a)
having isocyanate group is preferably from 0.5 wt % to 40 wt %,
more preferably from 1 wt % to 30 wt %, and further preferably from
2 wt % to 20 wt %. If the content of polyisocyanate (3) is too
small, hot offset resistance may be degraded, and a compatibility
of thermostable preservability of the toner and low-temperature
fixability of the toner may deteriorate. If the content of
polyisocyanate (3) is too great, low-temperature fixability of the
toner may deteriorate.
[0250] The number of isocyanate group contained in one molecule of
the prepolymer (a) having isocyanate group is preferably at least
1, more preferably an average of 1.5 to 3, and further preferably
an average of 1.8 to 2.5. If the number of isocyanate group per
molecule is less than 1, the molecular weight of urea-modified
polyester becomes lower, by which hot offset resistance may be
degraded.
[0251] Examples of the amine (b) include diamine (B1), tirvalent or
more polyamine (B2), amino alcohol (B3), amino mercaptan (B4),
amino acid (B5), and compound (B6) of B1 to B5 in which amino group
is blocked.
[0252] Examples of the diamine (B1) include aromatic diamine (e.g.,
phenylene diamine, diethyl toluene diamine, 4,4'
diaminodiphenylmethane); alicyclic diamine (e.g.,
4,4'-diamino-3,3'dimethyldicyclohexylmethane, diaminecyclohexane,
isophorone diamine); and aliphatic diamine (e.g., ethylene diamine,
tetramethylene diamine, hexamethylene diamine). Examples of the
tirvalent or more polyamine (B2) include diethylene triamine,
triethylene tetramine. Examples of the amino alcohol (B3) include
ethanolamine and hydroxyethylaniline. Examples of the amino
mercaptan (B4) include aminoethyl mercaptan and aminopropyl
mercaptan. Examples of the amino acid (B5) include aminopropionic
acid and aminocaproic acid. Examples of the compound (B6), in which
amino group of B1 to B5 is blocked, include ketimine compound and
oxazoline compound obtained from amines of B1 to B5 or ketones
(e.g., acetone, methyl ethyl ketone, methyl isobutyl ketone). The
preferable amine (b) is B1 alone or a mixture of B1 and a small
amount of B2.
[0253] Further, a reaction inhibitor can be used, as required, for
an elongation reaction to adjust a molecular weight of
urea-modified polyester. Examples of the reaction inhibitor include
monoamine (e.g., diethylamine, dibuthylamine, buthylamine,
laurylamine) and compound (e.g., ketimine compound), in which
monoamine is blocked.
[0254] A ratio of the amine (b) is preferably from 1/2 to 2/1, more
preferably from 1.5/1 to 1/1.5, and further preferably from 1.2/1
to 1/1.2 as an equivalent ratio of [NCO]/[NHx] of isocyanate group
[NCO] in the prepolymer (a) having isocyanate group and amino group
[NHx] in the amine (b). If the [NCO]/[NHx] becomes too great or too
small, a molecular weight of urea-modified polyester (i) becomes
lower, and hot offset resistance may be degraded. In an exemplary
embodiment, the urea-modified polyester (i) may have an urea bond
and an urethane bond. A molar ratio of urea bond content and
urethane bond content is preferably from 100/0 to 10/90, more
preferably from 80/20 to 20/80, and further preferably from 60/40
to 30/70. If the molar ratio of urea bond becomes too small, hot
offset resistance may be degraded.
[0255] The modified polyester such as urea-modified polyester (i),
to be used for toner particles, can be manufactured by these
reactions. The urea-modified polyester (i) can be prepared by a one
shot method or a prepolymer method, for example. The weight-average
molecular weight of the urea-modified polyester (i) is preferably
10,000 or more, more preferably from 20,000 to 10,000,000, and
further preferably from 30,000 to 1,000,000. If the weight-average
molecular weight is less than 10,000, hot offset resistance may be
degraded. Further, the number average molecular weight of
urea-modified polyester (i) is not particularly limited when an
unmodified polyester (ii), to be described later, is used. In such
a case, the number average molecular weight of the urea-modified
polyester (i) is set to a given value which can obtain the
aforementioned weight-average molecular weight.
[0256] When the urea-modified polyester (i) is used alone, the
number average molecular weight is preferably 20,000 or less, more
preferably from 1,000 to 10,000, and further preferably from 2,000
to 8,000. If the number average molecular weight becomes too great,
low-temperature fixability of the toner may deteriorate and
glossiness of images may be deteriorated when used for full-color
image forming.
[0257] In an exemplary embodiment, the urea-modified polyester (i)
can be used alone, and the urea-modified polyester (i) can be used
with unmodified polyester (ii) as binder resin component. By using
the urea-modified polyester (i) with the unmodified polyester (ii),
low-temperature fixability of the toner and glossiness of full
color image can be preferably enhanced compared to a case using the
urea-modified polyester (i) alone.
[0258] Examples of the unmodified polyester (ii) include
polycondensation product of the polyol (1) and polycarboxylic acid
(2) as similar to the urea-modified polyester (i), and preferred
compounds are the same as urea-modified polyester (i). Further, the
unmodified polyester (ii) may not limited to unmodified polyester,
but may also include compounds modified by chemical bond other than
urea bond, such as urethane bond. From a viewpoint of
low-temperature fixability of the toner and hot offset resistance,
it is preferable that the urea-modified polyester (i) and the
unmodified polyester (ii) are at least partially soluble each
other. Accordingly, it is preferable that polyester component of
(i) and (ii) have similar compositions. When (ii) is mixed with
(i), a weight ratio of (i) and (ii) is preferably from 5/95 to
80/20, more preferably from 5/95 to 30/70, further preferably from
5/95 to 25/75, and still further preferably from 7/93 to 20/80. If
the weight ratio of (i) is too small, such as less than 5 wt %, hot
offset resistance may be degraded, and a compatibility of
thermostable preservability of the toner and low-temperature
fixability of the toner may deteriorate.
[0259] The peak molecular weight of (ii) is preferably from 1,000
to 30,000, more preferably from 1,500 to 10,000, and further
preferably from 2,000 to 8,000. If the peak molecular weight
becomes too small, thermostable preservability of the toner may
deteriorate. If the peak molecular weight becomes too great,
low-temperature fixability of the toner may deteriorate.
[0260] A hydroxyl group value of (ii) is preferably 5 or more, more
preferably from 10 to 120, and further preferably from 20 to 80. If
the hydroxyl group value is too small, a compatibility of
thermostable preservability of the toner and low-temperature
fixability of the toner may deteriorate. An acid value of (ii) is
preferably from 1 to 30, and more preferably from 5 to 20. By
having such acid value, the unmodified polyester (ii) can be easily
set to a negative charged condition.
[0261] A glass-transition temperature (Tg) of the binder resin is
preferably from 50 to 70 degrees Celcius, and more preferably from
55 to 65 degrees Celcius. If the glass-transition temperature is
too low, toner particles may be easily subjected to a blocking
phenomenon at a higher temperature, which is not preferable. If the
glass-transition temperature is too high, low-temperature
fixability of the toner may deteriorate.
[0262] Under the existence of the urea-modified polyester resin,
toner particles of an exemplary embodiment has a good level of
thermostable preservability even if the glass-transition
temperature is low compared to known polyester-based toner
particles.
[0263] The temperature (TG') that the binder resin has a storage
modulus of 10,000 dyne/cm.sup.2 at a measurement frequency of 20 Hz
is preferably 100 degrees Celcius or more, and more preferably from
110 to 200 degrees Celcius. If the temperature TG' is too low, hot
offset resistance may be degraded.
[0264] The temperature (T.eta.) that the binder resin has a
viscosity of 1,000 poises at a measurement frequency of 20 Hz is
preferably 180 degrees Celcius or less, and more preferably from 90
to 160 degrees Celcius. If the temperature T.eta. becomes too high,
low-temperature fixability of the toner may deteriorate.
Accordingly, from a viewpoint of compatibility of low-temperature
fixability of the toner and hot offset resistance, TG' is
preferably set higher than T.eta.. In other words, a difference
between TG' and T.eta. ("TG'-T.eta.") is preferably 0 degrees
Celcius or more, more preferably 10 degrees Celcius or more, and
further preferably 20 degrees Celcius or more. Such difference
between TG' and T.eta. has no specific upper limit value. From a
viewpoint of compatibility of thermostable preservability of the
toner and low-temperature fixability of the toner, the difference
between T.eta. and TG' is preferably 0 to 100 degrees Celcius, more
preferably from 10 to 90 degrees Celcius, and further preferably
from 20 to 80 degrees Celcius.
[0265] The binder resin can be manufactured by the following
method. Polyol (1) and polycarboxylic acid (2) are heated at a
temperature of 150 to 280 degrees Celcius under a presence of a
known esterification catalyst (e.g., tetrabutoxytitanate,
dibuthyltin oxide), and water is distilled under depressurized
condition, as required, to obtain polyester having hydroxyl group.
Then, such polyester is reacted with polyisocyanate (3) at a
temperature of 40 to 140 degrees Celcius to obtain prepolymer (a)
having isocyanate group. The prepolymer (a) is reacted with an
amine (b) at a temperature of 0 to 140 degrees Celcius to obtain
urea-modified polyester. When the polyester is reacted with the
polyisocyanate (3) and when the prepolymer (a) is reacted with the
amine (b), a solvent can be used, as required. Examples of solvent
include aromatic solvent (e.g., toluene, xylene); ketones (e.g.,
acetone, methyl ethyl ketone, methyl isobutyl ketone); esters
(e.g., acetic ether); amide (e.g., dimethyl formamide, dimethyl
acetamide), and ether (e.g., tetrahydrofuran), which are inactive
to the polyisocyanate (3). When unmodified polyester (ii) is also
used, unmodified polyester (ii) is prepared with a method similarly
applied to polyester having hydroxyl group, and the unmodified
polyester (ii) is solved and mixed with a solution having the
modified polyester (i), reacted already.
[0266] Although the toner particles used in an exemplary embodiment
can be manufactured by a following method, other methods can be
used. As an aqueous medium, water may be used singly or in
combination with a water-soluble solvent. Examples of the
water-soluble solvent include alcohol (e.g., methanol, isopropanol,
ethylene glycol), dimethyl formamide, tetrahydrofuran, cellosolves
(e.g., methyl cellosolve), and lower ketones (e.g., acetone, methyl
ethyl ketone).
[0267] The toner particles may be formed by reacting a dispersed
prepolymer (a) having isocyanate group with amine (b) in the
aqueous medium, or by using the urea-modified polyester (i)
prepared in advance.
[0268] In the aqueous medium, a dispersion having the urea-modified
polyester (i) and prepolymer (a) can be stably formed by adding
compositions of toner materials having the urea-modified polyester
(i) and prepolymer (a) in the aqueous medium, and by dispersing
them by shear force. Toner materials including prepolymer (a) and
other toner composition such as a colorant, a colorant master
batch, a release agent, a charge control agent, an unmodified
polyester resin, or the like can be mixed as a dispersion in the
aqueous medium. However, it is more preferable to mix the toner
materials in advance, and then to add such mixture in the aqueous
medium to disperse such toner materials. Further, other toner
materials such as a colorant, a release agent, a charge control
agent, or the like are not necessarily mixed when toner particles
are formed in the aqueous medium. Such other toner materials can be
added after forming toner particles. For example, after forming
toner particles having no colorant, a colorant can be added to the
toner particles with known dyeing method.
[0269] The dispersion method includes known methods, such as a
low-speed shearing method, a high-speed shearing method, a friction
method, a high-pressure jet method, an ultrasonic wave method, for
example, which can be selected depending on purpose. A high-speed
shearing method is preferably used to obtain dispersed particles
having a particle diameter of from 2 .mu.m to 20 .mu.m. Although a
dispersing machine using high-speed shearing method can be rotated
at any speed, the dispersing machine is preferably rotated at 1,000
rpm to 30,000 rpm (rotation per minute), and more preferably 5,000
rpm to 20,000 rpm. Although a dispersion time can be set any time,
such dispersion time is usually set to 0.1 to 5 minutes for a batch
method. The dispersion temperature is usually set to from 0 to 150
degrees Celcius (under pressurized condition), and more preferably
from 40 to 98 degrees Celcius. A higher dispersion temperature is
preferable because the urea-modified polyester (i) and prepolymer
(a) can be easily dispersed when a dispersion solution has a lower
viscosity.
[0270] The use amount of the aqueous medium with respect to 100
weight parts of toner composition having the urea-modified
polyester (i) and prepolymer (a) is preferably 50 to 2,000 weight
parts, and more preferably 100 to 1,000 weight parts. If the use
amount of the aqueous medium is too small, toner compositions may
not be dispersed effectively, by which toner particles having a
given particle diameter cannot be obtained. If the use amount of
the aqueous medium is too great, the manufacturing may not be
conducted economically. Further, a dispersing agent can be used, as
required. A dispersing agent is preferably used to obtain sharper
particle-size distribution and stable dispersing condition.
[0271] In the process of synthesizing the urea-modified polyester
(i) from the prepolymer (a), the amine (b) can be added and reacted
in the aqueous medium before dispersing the toner compositions.
Alternatively, the amine (b) can be added in the aqueous medium
after dispersing the toner compositions to cause a reaction on an
interface of particles. In this case, urea-modified polyester is
formed preferentially on a surface of the toner particles prepared
in the aqueous medium, by which a concentration gradient of
urea-modified polyester may be set for a toner particle. For
example, the concentration of urea-modified polyester may be set
higher in a sub-surface portion of a toner particle and set lower
in a center portion of a toner particle.
[0272] Dispersant for emulsifying or dispersing an oil phase having
dispersed toner components to an aqueous phase may be anionic
surfactant, cationic surfactant, nonionic surfactant, or
zwitterionic surfactant. Examples of the anionic surfactant include
alkyl benzene sulfonate salt, .alpha.-olefin sulfonate salt, alkyl
salt, and phosphate ether salt. Examples of the cationic surfactant
include amine salt surfactant, and quaternary ammonium salt
cationic surfactant. Examples of the amine salt surfactant include
alkylamine salt, amino alcohol fatty acid derivative, polyamine
fatty acid derivative, and imidazoline. Examples of the quaternary
ammonium salt cationic surfactant include alkyl trimethyl ammonium
salt, dialkyldimethyl ammonium salt, alkyl dimethylbenzyl ammonium
salt, pyridinium salt, alkyl isoquinolinium salt, and benzethonium
chloride. Examples of the nonionic surfactant include aliphatic
acid amide derivative, and polyalcohol derivative. Examples of the
zwitterionic surfactant include alanine,
dodecyldi(aminoethyl)glycine, di(octylaminoethyl)glycine, and
N-alkyl N,N-dimethylammonium betaine.
[0273] Among these, the surfactant having fluoroalkyl group is
preferably used to have favorable effect with a small amount.
Examples of the anionic surfactant having the fluoroalkyl group
include fluoroalkyl carboxylic acid having a carbon number of 2 to
10 or metal salt thereof, disodium perfluorooctane sulfonyl
glutamic acid, sodium 3-[.omega.-fluoroalkyl (C6 to C11)
oxy]-1-alkyl (C3 to C4) sulfonate, sodium 3-[.omega.-fluoroalkanoyl
(C6 to C8)-N-ethylamino]-1-propane sulfonate, fluoroalkyl (C11 to
C20) carboxylic acid or its metal salt, perfluoroalkyl carboxylic
acid (C7 to C13) or its metal salt, perfluoroalkyl (C4 to C12)
sulfonate or its metal salt, perfluorooctane sulfonic acid
diethanolamide, N-propyl-N-(2-hydroxyethyl)perfluorooctane
sulfonamide, perfluoroalkyl (C6 to C10) sulfonamide propyl
trimethyl ammonium salt, perfluoroalkyl (C6 to C10)-N-ethylsulfonyl
glycine salt, and mono perfluoroalkyl (C6 to C16) ethylphosphate
ester.
[0274] Examples of trade name of surfactant having the fluoroalkyl
group include SURFLON S-11, S-12, S-13 (manufactured by Asahi Glass
Co., Ltd); FLUORAD FC-93, FC-95, FC-98, FC-129 (manufactured by
Sumitomo 3M Co., Ltd); UNIDINE DS-101, DS-102 (manufactured by
Daikin Industries, Ltd); MEGAFACE F-110, F-120, F-113, F-191,
F-812, F-833 (manufactured by Dainippon Ink & Chemicals, Inc.);
EKTOP EF-102, 103, 104, 105, 112, 123A, 123B, 306A, 501, 201, 204
(manufactured by Tochem Products Co., Ltd); and FTERGENT F-100,
F150 (manufactured by Neos Co., Ltd).
[0275] Examples of the cationic surfactant include aliphatic
primary, secondary, or tertiary amine having fluoroalkyl group,
aliphatic quaternary ammonium salt, such as perfluoroalkyl (C6 to
C10) sulfonamide propyl trimethyl ammonium salt, benzalkonium salt,
benzethonium chloride, pyridinium salt, and imidazolinium salt.
Trade names of the cationic surfactant include SURFLON S-121
(manufactured by Asahi Glass Co., Ltd); FLUORAD FC-135
(manufactured by Sumitomo 3M Co., Ltd); UNIDINE DS-202
(manufactured by Daikin Industries, Ltd), MEGAFACE F-150, F-824
(manufactured by Dainippon Ink & Chemicals, Inc.); EKTOP EF-132
(manufactured by Tochem Products Co., Ltd); and FTERGENT F-300
(manufactured by Neos Co., Ltd).
[0276] Examples of the inorganic compound dispersing agent having
lower water solubility include tricalcium phosphate, calcium
carbonate, titanium oxide, colloidal silica, and
hydroxyapatite.
[0277] Further, high polymer protective colloid can be used to
stabilize a dispersion droplet. Examples of the high polymer
protective colloid include acids, (meth) acrylic monomer having
hydroxyl group, vinyl alcohol or vinyl alcohol ether, ester
compound having vinyl alcohol and carboxyl group, amide compound or
its methylol compound, chloride, homopolymer or copolymer having
nitrogen atom or heterocyclic ring of nitrogen atom,
polyoxyethylene, and cellulose.
[0278] Examples of the acids include acrylic acid, methacrylic
acid, .alpha.-cyanoacrylic acid, .alpha.-cyanomethacrylic acid,
itaconic acid, crotonic acid, fumaric acid, maleic acid, and maleic
anhydride. Examples of the (meth) acrylic monomer having hydroxyl
group include .beta.-hydroxyethyl acrylic acid, .beta.-hydroxyethyl
methacrylic acid, .beta.-hydroxypropyl acrylic acid,
.beta.-hydroxypropyl methacrylic acid, .gamma.-hydroxypropyl
acrylic acid, .gamma.-hydroxypropyl methacrylic acid,
3-chloro-2-hydroxypropyl acrylic acid, 3-chloro-2-hydroxypropyl
methacrylic acid, dieethylene glycol monoacrylic ester, diethylene
glycol monomethacrylic acidester, glycerin monoacrylic ester,
glycerin monomethacrylic ester, N-methylol acrylamide, and
N-methylol methacrylamide. Examples of the vinyl alcohol or vinyl
alcohol ether include vinyl methyl ether, vinyl ethyl ether, and
vinyl propyl ether. Examples of the ester compound having vinyl
alcohol and carboxyl group include vinyl acetate, propionic
acidvinyl, and vinyl butyrate. Examples of the amide compound or
its methylol compound include acrylamide, methacrylamide, diacetone
acrylamide acid, or methylol compound thereof. Examples of the
chloride include acrylic acid chloride, and methacrylic acid
chloride. Examples of the homopolymer or copolymer having nitrogen
atom or heterocyclic ring of nitrogen atom include vinylviridin,
vinylpyrrolidone, vinylimidazole, and ethyleneimine. Examples of
the polyoxyethylene include polyoxyethylene, polyoxypropylene,
polyoxyethylene alkylamine, polyoxypropylenealkylamine,
polyoxyethylene alkylamide, polyoxypropylenealkylamide,
polyoxyethylene nonyl phenyl ether, polyoxyethylene lauryl phenyl
ether, polyoxyethylene stearyl phenyl ester, and polyoxyethylene
nonyl phenyl ester. Examples of the cellulose include methyl
cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose.
[0279] When preparing the aforementioned dispersion solution, a
dispersion stabilizer can be used, as required. Such dispersion
stabilizer include compound such as calcium phosphate salt, which
can be solved in acid or alkali. When such dispersion stabilizer is
used, calcium phosphate salt may be removed from fine particles by
dissolving calcium phosphate salt using acid, such as hydrochloric
acid, and then washing dispersion solution, or calcium phosphate
salt may be removed from fine particles through decomposition by
enzyme. If the dispersion agent is used, the dispersion agent can
be remained on surface of toner particles. However, such dispersion
agent is preferably washed and removed from toner particles after
an elongation and/or cross-linking reaction to set preferable toner
charge performance.
[0280] Further, to decrease the viscosity of toner composition, a
solvent, which can solve the urea-modified polyester (i) and
prepolymer (a), can be used. Such solvent is preferably used to
obtain a sharper particle-size distribution. Such solvent may be
preferably volatile, by which solvent can be removed easily.
Examples of the solvent include toluene, xylene, benzene,
tetrachloride carbon, dichloromethane, 1,2-dichloroethane,
1,1,2-trichloroethane, trichloroethylene, chloroform,
monochlorobenzene, dichloroethylidene, methyl acetate, acetic
ether, methyl ethyl ketone, and methyl isobutyl ketone. These can
be used alone or in combination. Among these, aromatic solvent such
as toluene and xylene, halogenated hydrocarbon such as
dichloromethane, 1,2-dichloroethane, chloroform, and tetrachloride
carbon are preferably used, and aromatic solvent such as toluene
and xylene is more preferably used. The use amount of the solvent
with respect to the prepolymer (a) of 100 weight parts is
preferably from 0 to 300 weight parts, more preferably from 0 to
100 weight parts, and further preferably from 25 to 70 weight
parts. When the solvent is used, the solvent is heated and removed
under a normal or reduced pressure condition after an elongation
and/or cross-linking reaction.
[0281] An elongation and/or cross-linking reaction time is
determined based on reactivity of the isocyanate group of the
prepolymer (a) and the amine (b). Such reaction time is usually 10
minutes to 40 hours, and preferably from 2 hours to 24 hours. The
reaction temperature is preferably from 0 to 150 degrees Celcius,
and more preferably from 40 to 98 degrees Celcius. Further, a known
catalyst, such as dibuthyltin laurate and dioctyltin laurate, can
be used, as required.
[0282] To remove an organic solvent from the emulsified dispersion
solution, the emulsified dispersion solution is gradually heated to
a higher temperature to vaporize and remove the organic solvent
from the solution. Alternatively, an emulsified dispersion solution
may be sprayed in a dry atmosphere to remove an organic solvent
from droplets to form fine toner particles, and aqueous dispersing
agent is also vaporized and removed. Such dry atmosphere may be a
heated gas atmosphere using air, nitrogen, carbon dioxide,
combustion gas, or the like. Such heated gas atmosphere may be
heated to a temperature greater than a boiling point of solvent to
be used. Targeted quality of toner particles can be obtained by a
spray dryer, a belt dryer, or a rotary kiln with a shorter
time.
[0283] When an emulsified dispersion solution has a broader
particle-size distribution, such broader particle-size distribution
can be segmented in a plurality of sizes after washing and drying
the emulsified dispersion solution to obtain uniformly sized
particles. Such segmentation process for separating fine particles
size by size can be conducted to the dispersion solution by a
cyclone method, a decanter method, or a centrifugal separation
method or the like. Although the segmentation process can be
conducted to dried particles, obtained by drying the dispersion
solution, such segmentation process can be preferably conducted to
the dispersion solution from a viewpoint of efficiency. Fine
particles, obtained by the segmentation process but not used for
product or not so fine particles may be reused in a kneading
process to form particles. In such a case, such unnecessary fine
particles or not so fine particles may be wet. It is preferable to
remove the dispersing agent from the obtained dispersion solution
as much as possible, and such removal of dispersing agent is
preferably conducted when the segmentation process is conducted,
for example.
[0284] Such obtained dried toner particles may be mixed other
particles, such as a release agent, a charge control agent, a
plasticizer, and a colorant, and then a impact force may be applied
to the mixed particles to fix or fuse other particles on the
surface of toner particles. Such fixed other particles may not be
separated from the surface of toner particles so easily.
[0285] Specifically, a mixture of particles is applied with an
impact force using an impeller vane rotating at a high speed, or a
mixture of particles is introduced in a high speed air stream for
accelerating particles, and accelerated particles are impacted one
another or impacted against an impact plate. Examples of such
machines are Ong Mill (manufactured by Hosokawa Micron Corp.), a
modified I-type Mill (manufactured by Nippon Pneumatic Mfg. Co.,
Ltd) using reduced pulverization air pressure, Hybridizaition
System (manufactured by Nara Kikai Seisakusho), Cryptron System
(manufactured by Kawasaki Heavy Industries, Ltd), and an automatic
mortar, for example.
[0286] Further, conventional colorants such as pigment and dye can
be used as a colorant for the toner particles. Such colorant
includes carbon black, lamp black, iron black, ultramarine blue,
nigrosin dye, aniline blue, phthalocyanine blue, phthalocyanine
green, Hansa yellow G, rhodamine 6C lake, chaclo-oil blue, chrome
yellow, quinacridone red, benzidine yellow, and rose bengal, for
example. These can be used alone or in combination.
[0287] Further, if magnetic property is to be provided to toner
particles, toner particles may be contained with magnetic component
such as ferric oxide (e.g., ferrite, magnetite, maghemite) or metal
and metal alloy of iron, cobalt, nickel, or the like. These
magnetic components may be used alone or in combination. Further,
such magnetic component may be used as a colorant component.
[0288] Further, the colorant used with the toner particles
preferably has the number average particle diameter of 0.5 .mu.m or
less, more preferably 0.4 .mu.m or less, and further preferably 0.3
.mu.m or less. If the number-average particle diameter becomes too
large, pigments may not be dispersed at an adequate level, and a
preferable transparency may not be obtained. If the number average
particle diameter becomes smaller, such fine colorant particles
have a diameter effectively smaller than a half-wave length of
visible light, by which such fine colorant particles may not affect
reflection and absorption of light. Accordingly, such fine colorant
particles may be useful for attaining a good level of color
reproducibility and transparency of an OHP (overhead projector)
sheet having an image.
[0289] If particles having a larger particle diameter are included
in colorant in large amount, such larger particles may block
transmission of incident light or scatter incident light, by which
brightness and vividness of a projected image of OHP sheet may
become lower. Further, if such larger particles are included in
colorant in large amount, colorant may drop from the surface of
toner particles, and thereby causing problems such as fogging, drum
contamination, defective cleaning. Specifically, a ratio of
colorant having a particle diameter greater than 0.7 .mu.m is
preferably 10% or less, and more preferably 5% or less of all
colorant.
[0290] Further, colorant may be mixed with a binding resin and a
moistening agent, and kneaded with the binding resin to adhere the
colorant to the binding resin. When the colorant is mixed with the
binding resin, such colorant may be dispersed more effectively, and
thereby a particle diameter of colorant dispersed in toner
particles can be set smaller. Accordingly, a better transparency of
an OHP (overhead projector) sheet having an image can be obtained.
The binding resin used for such kneading may include resin used as
a binding resin for toner, but not limited thereto.
[0291] A mixture of the binding resin, colorant, and moistening
agent can be mixed by using a blending machine, such as Henschel
mixer, and then the mixture is kneaded by a kneading machine having
two or three rolls at a temperature set lower than a melting
temperature of the binding resin, by which kneaded mixture of the
binding resin and colorant can be obtained. Further, the moistening
agent may be water, an organic solvent, such as acetone, toluene,
butanone in view of solubility of a binding resin and wet-ability
with a colorant, and water is preferably used in view of dispersion
performance of colorant. Water is preferable from a viewpoint of
environmental load, and keeping dispersion stability of colorant in
the following toner manufacturing process. Such process may
preferably decrease a particle diameter of colorant particles
included in toner particles, and colorant particles can be
dispersed more uniformly. Accordingly, color reproducibility of a
projected image of OHP sheet can be enhanced.
[0292] Further, the toner particles may preferably include a
release agent in addition to the binder resin and the colorant.
Examples of the release agent include polyolefin wax (e.g.,
polyethylene wax, polypropylene wax); long-chain hydrocarbon (e.g.,
paraffin wax, southall wax); and wax carbonyl group. Among these,
wax having carbonyl group is preferable.
[0293] Examples of the wax having carbonyl group include
ployalkanoic acid ester (e.g., camauba wax, montan wax,
trimethylolpropane tribehenate, pentaerythritol tetraibehenate,
pentaerythritol diacetate dibehenate, glycerin tribehenate,
1,18-octadecanediol distearate); ployalkanol ester (e.g.,
trimellitic acid tristearyl, distearyl maleate); ployalkanoic acid
amide (e.g., ethylenediamine dibehenylamide); polyalkylamide (e.g.,
tristearylamide trimellitate); and dialkyl ketone (e.g., distearyl
ketone). Among these, ployalkanoic acid ester is preferable.
[0294] The melting point of the release agent is preferably from 40
to 160 degrees Celcius, more preferably from 50 to 120 degrees
Celcius, and further preferably from 60 to 90 degrees Celcius. If
the melting point of the release agent is too low, such release
agent may affect thermostable preservability of the toner. If the
melting point of the release agent is too high, such release agent
may more likely cause cold offset when a fixing process is
conducted under low temperature.
[0295] The viscosity of the melted release agent measured at a
temperature higher than the melting point for 20 degrees Celcius
preferably has a value of from 5 to 1,000 cps, and more preferably
from 10 to 100 cps. If the melted viscosity becomes too great, such
release agent may not improve hot offset resistance and low
temperature fixability of the toner. A content of the release agent
in the toner particles is preferably 0 wt % to 40 wt %, and more
preferably from 3 wt % to 30 wt %.
[0296] Further, toner particles may include a charge control agent
to enhance charge amount and charging speed of toner particles, as
required. If the charge control agent is a color material, such
charge control agent may change the color of toner particles.
Accordingly, colorless material or whitish material is preferably
used. Examples of the charge control agent include triphenylmethane
dye, chelate molybdate pigment, rhodamine dye, alkoxy amine,
quaternary ammonium salt (including fluorine modified quaternary
ammonium salt), alkylamide, phosphorus alone or phosphorus
compound, tungsten alone or tungsten compound, fluorine-based
activator, salicylic acid metal salt, and metal salt of salicylic
acid derivative.
[0297] Example trade names of the charge control agent include
Bontron P-51 as quaternary ammonium salt, E-82 as oxynaphthoic acid
metal complex, E-84 as salicylic acid metal complex, E-89 as phenol
condensate (manufactured by Orient Chemical 100 Industries, Ltd.);
TP-302, TP-415 as quaternary ammonium salt molybdenum complex
(manufactured by Hodogaya Chemical Industries, Ltd.); Copy Charge
PSY VP2038 as quaternary ammonium salt, Copy Blue PR as triphenyl
methane derivative, Copy Charge NEG VP2036 and Copy Charge NX VP434
as quaternary ammonium salt (manufactured by Hoechst Co.,
Ltd.);LRA-901, LR-147 as boron complex (both manufactured by Japan
Carlit Co., Ltd.), quinacridone, azo pigment, and polymer compound
having functional group such as sulfonic acid group, carboxyl
group, quaternary ammonium salt, or the like.
[0298] The adding amount of the charge control agent is determined
based on toner manufacturing condition such as types of binder
resins, presence or absence of additives, and a dispersion method,
or the like. The charge control agent is preferably used in a range
of from 0.1 to 10 weight parts, and more preferably from 0.2 to 5
weight parts with respect to the binder resin of 100 weight parts.
If the adding amount of the charge control agent becomes too great,
the toner particles may be charged too high, by which an effect of
charge control agent is reduced and the toner particles may be
attracted to a developing roller with a greater electrostatic
attraction force. Therefore, a developing agent may have a lower
fluidity, and result in a lower image concentration.
[0299] Such charge control agent can be melted and kneaded with a
resin in a master batch to disperse the charge control agent, or
may be added to an organic solvent when to dissolute and disperse
the charge control agent, or may be solidified on the surface of
toner particles after toner particles are formed.
[0300] Further, when dispersing toner compositions in an aqueous
medium during a toner manufacturing process, fine resin particles
may be added to a solution to stabilize dispersion condition. Such
fine resin particles may be any resins, which can be used for
dispersion in an aqueous medium, and may be thermoplastic resin or
thermosetting resin. Examples of the fine resin particles include
vinyl resin, polyurethane resin, epoxy resin, polyester resin,
polyamide resin, polyimide resin, silicone resin, phenol resin,
melamine resin, urea resin, aniline resin, ionomer resin, and
polycarbonate resin. These can be used alone or in combination.
Among these, vinyl resin, polyurethane resin, epoxy resin,
polyester resin or combination of these are preferably used to
obtain spherical fine particles in an aqueous dispersion. Examples
of the vinyl resin include homopolymer or copolymer of vinyl
monomers, and may be styrene (meth)acrylic acid ester resin,
copolymer of styrene/butadiene, copolymer of (meth)acrylic
acid-acrylic acid ester, copolymer of styrene/acrylonitrile,
copolymer of styrenemaleic anhydride, and copolymer of styrene
(meth)acrylic acid, but not limited those.
[0301] Further, inorganic fine particles may be preferably used as
external additives to facilitate fluidity, developing performance,
charged performance of toner particles. Such inorganic fine
particles preferably have a primary particle diameter of 5 nm
(nanometer) to 2 .mu.m, and more preferably 5 nm to 500 nm.
Further, Such inorganic fine particles preferably have a specific
surface area of 20 m.sup.2/g to 500 m.sup.2/g measured by the BET
method. Such inorganic fine particles are preferably added to the
toner particles with 0.01 wt %, to 5 wt %, and more preferably from
0.01 wt % to 2.0 wt %. Examples of the inorganic fine particles
include silica, alumina, titanium oxide, barium titanate, magnesium
titanate, calcium titanate, strontium titanate, zinc oxide, tin
oxide, silica sand, clay, mica isinglass, sand-lime, diatomite,
chrome oxide, cerium oxide, colcothar, antimony trioxide, magnesium
oxide, zirconium oxide, barium sulfate, barium carbonate, calcium
carbonate, silicon carbide, and silicon nitride.
[0302] In addition, polymer fine particles obtained by, for
example, a soap-free emulsion polymerization, a suspension
polymerization, or a dispersion polymerization can be used. Such
polymer fine particles may be polystyrene, methacrylic acid ester,
copolymer of acrylic acid ester, polycondensation polymer of
silicone, polycondensation polymer of benzoganamine,
polycondensation polymer of nylon, and polymer particles prepared
from thermosetting resin, for example.
[0303] Such external additives are subjected to a surface treatment
to enhance hydrophobicity, by which a deterioration of fluidity and
charged performance of toner particles under high-humidity
environment can be reduced. Examples of preferable surface
treatment agent include silane coupling agent, silylating agent,
silane coupling agent having fluorinated alkyl group, organic
titanate coupling agent, aluminum coupling agent, silicone oil, and
modified silicone oil.
[0304] Further, a cleaning improving agent may be added to toner
composition, to facilitate removal of developing agent remaining on
the photoconductor drum 1 or an intermediate transfer member after
transfer process. Examples of the cleaning improving agent include
aliphatic metal salt (e.g., zinc stearate, calcium stearate,
stearic acid); and polymer fine particles manufactured by a
soap-free emulsion polymerization (e.g., polymethyl methacrylate
fine particles, polystyrene fine particles). Such polymer fine
particles have relatively narrower particle-size distribution, and
particles having volume-average particle diameter of 0.01 .mu.m to
1 .mu.m is preferable.
[0305] By using such toner particles having a good level of
developing performance, a higher quality toner image can be
produced in stable manner. However, toner particles, not
transferred to a transfer member (or recording member) or an
intermediate transfer member by a transfer unit but remaining on
the photoconductor drum 1, may not be effectively removed by a
cleaning unit because toner particles have fine spherical shape,
and such toner particles may not be recovered by the cleaning unit.
Although toner particles can be removed from the photoconductor
drum 1 by pressing a particle remover such as cleaning blade
against the photoconductor drum 1 with a greater force, for
example, such configuration may shorten a lifetime of the
photoconductor drum 1 or cleaning unit, and may not be preferable
from a viewpoint of energy saving. However, if a pressure of the
cleaning blade pressed against the photoconductor drum 1 is
reduced, toner particles or small-sized carrier particles cannot be
removed from the photoconductor drum 1 effectively, and such
particles may cause damages on the photoconductor drum 1, by which
an image forming apparatus may not produce images effectively.
[0306] Although toner for producing higher quality image, prepared
by a polymerization method is used for the above described image
forming apparatus, toner prepared by another method, such as
indefinite shaped toner prepared by a pulverization method, can
also be used for the image forming apparatus. Such toner may be
preferably used to enhance a lifetime of image forming
apparatus.
[0307] Further, in an exemplary embodiment, in addition to the
above-described toner particles used for obtaining high quality
images, an image forming apparatus can be used with irregular
shaped toner particles prepared by a pulverization method, which
may be useful for extending a lifetime of apparatus. Materials for
such toner particles may not be limited to any specific materials,
but materials used commonly for electrophotography can be used.
[0308] Examples of binding resin used for the pulverized toner
particles include styrene or homopolymers of styrene derivative
substitution (e.g., polystyrene, polyp-chlorostyrene, polyvinyl
toluene); styrene copolymer (e.g., styrene/p-chlorostyrene
copolymer, styrene/propylene copolymer, styrene/vinyl toluene
copolymer, styrene/vinyl naphthalen copolymer, styrene/acrylic acid
methyl copolymer, styrene/acrylic acid ethyl copolymer,
styrene/acrylic acid buthyl copolymer, styrene/acrylic acid octyl
copolymer, styrene/methacrylic acid methyl copolymer,
styrene/methacrylic acid ethyl copolymer, styrene/methacrylic acid
buthyl copolymer, styrene/.alpha.-chloromethacrylic acid methyl
copolymer, styrene/acrylonitrile copolymer, styrene/vinyl methyl
ketone copolymer, styrene/butadiene copolymer, styrene/isoprene
copolymer, styrene/maleic acid copolymer); homopolymer or copolymer
of acrylic acid ester (e.g., polymethyl acrylate, polybuthyl
acrylate, polymethyl methacrylate, polybuthyl methacrylate
methacrylic acid); polyvinyl derivative (e.g., polyvinyl chloride,
polyvinyl acetate); polyester polymer, polyurethane polymer,
polyamide polymer, polyimide polymer, polyol polymer, epoxy
polymer, terpene polymer, aliphatic or alicyclic hydrocarbon resin,
and aromatic petroleum resin. These can be used alone or in
combination. Among these, styrene acrylic copolymer resin,
polyester resin, polyol resin are preferably used in view of
electrical property and cost, and polyester resin and polyol resin
are preferably used in view of a good level of fixing
performance.
[0309] The surface layer of the charging member such as charge
roller may include a resin component used as binding resin of the
toner particles, wherein such resin component may be linear
polyester resin composition, linear polyolresin composition, linear
styrene acrylic resin compositions or cross-linking composition of
these, and at least one of these may be used.
[0310] Such pulverized toner particles may be prepared as follows:
First, mix the aforementioned resin component and the
aforementioned colorant component, a wax component, a charge
control component, or the like, as required, then knead such
mixture at a temperature slightly lower than a melting temperature
of the resin component, and then cool the mixture. After segmenting
toner particles size by size, toner particles can be prepared. Such
toner particles may be further added with the aforementioned
external additives, as required.
[0311] Hereinafter, a description is given to experiment and its
results in detail using protective layer setting units prepared
according to an exemplary embodiment. It should be noted that
following Example 1 used in the experiment are just exemplary, and
other configuration can be devised.
[0312] FIG. 7 illustrates a schematic configuration of the
protective layer setting unit 2 used in the experiment. The
photoconductor drum used in the experiment was manufactured as
below.
Photoconductor Drum
[0313] An aluminum drum (conductive supporter) having a diameter of
30 mm was coated with an under layer, a charge generation layer, a
charge transport layer, and a surface layer in this order, and
dried to form the photoconductor drum having an under layer of 3.6
.mu.m thickness, a charge generation layer of about 0.14 .mu.m
thickness, a charge transport layer of 23 .mu.m thickness, and a
surface layer of about 3.5 .mu.m thickness. Such photoconductor
drum was manufactured for thirty drums. The surface layer was
coated using a spray method, and other layers were coated using a
dipping method. The surface layer was added with alumina having an
average particle diameter of 0.18 .mu.m with a weight ratio of 23.8
wt %.
Agent Bar No. 11
[0314] FT115 (synthesize wax manufactured by Nippon Seiro Co.,Ltd.)
of 90 weight part and TOPAS-TM (manufactured by manufactured by
Ticona) of 10 weight part were placed in a glass vessel having a
cap, and were agitated and melted at a temperature of 160 to 250
degrees Celcius using a hot stirrer. Then, the melted protective
agent was poured in an internal space of an aluminum metal mold,
having a size of 12 mm.times.8 mm.times.350 mm, heated to 115
degrees Celcius in advance. After cooling to 88 degrees Celcius on
a wooden table, the aluminum metal mold was cooled to 40 degrees
Celcius on an aluminum table. Then, the solidified product was
removed from the mold, and then cooled to an ambient temperature
while placing a weight on the product for preventing warping. After
that, an agent bar No. 11 having a size of 7 mm.times.8
mm.times.310 mm was prepared by cutting some portion of the
product. The agent bar No. 11 was attached with a double face tape
and fixed to a metal supporter.
[0315] Samples of the agent bar No. 11 and photoconductor were
analyzed by FT-IR Avatar370 (manufactured by Thermo Electron
Corporation, Thunder Dome) under a condition of one time
reflection, ATR prism of Ge, incident angle of 45.degree. for IR
spectrum analysis to obtain IR spectrum A and B, which is shown in
FIG. 8, wherein the IR spectrum A is for the photoconductor, and
the IR spectrum B is for the agent bar No. 11.
[0316] In the IR spectrum A of the photoconductor, the peak Pa1
attributed to polycarbonate bond was observed at 1770 cm.sup.-1,
and the peak Pa2 attributed to phenyl group was observed at 3040
cm.sup.-1. In the IR spectrum B of the agent bar No. 11, the peak
Pb1 attributed to methylene group was observed at 2850 cm.sup.-1,
and the peak Pb2 is observed at 2920 cm.sup.-1. When the
photoconductor was measured by the ATR, a measurement sample having
1 cm.times.1 cm size was cut from an aluminum base of the
photoconductor.
EXAMPLE 1-1
Methylene Index
[0317] The photoconductor, a brush roller No.2 (fiber having a
thickness of 10 denier, fiber density of 50,000 fibers per square
inch), and a urethane blade were assembled in a protective layer
setting unit (see FIG. 7). The agent bar No. 11 was pressed against
the brush with a spring force of 4.8 N to apply a protective agent
to photoconductors (1-1) to (1-5). The photoconductor and the brush
roller rotated at a linear velocity of 125 mm/sec and 146 mm/sec,
respectively.
[0318] After applying the protective agent for 120 minutes to
photoconductor (1-4) using the protective layer setting unit (11),
a sample of the photoconductor was sliced using a ultramicrotome
and TEM (transmission electron microscope) observation was
conducted, and it was found that the layer thickness of protective
agent was 20 nm to 50 nm based on TEM photo.
[0319] The photoconductors (1-1) to (1-5) were applied with the
protective agent by changing an application time (3, 10, 40, 120,
360 minutes), and samples of each the photoconductors were prepared
after applying the protective agent. After applying the protective
agent, samples of the photoconductors (1-1) to (1-5) were analyzed
by FT-IR Avatar370 (manufactured by Thermo Electron Corporation,
Thunder Dome) under a condition of one time reflection, ATR prism
of Ge, incident angle of 45.degree. for IR spectrum analysis to
obtain the IR spectrum C (see FIG. 8).
[0320] Based on the IR spectrum C, a peak area ratio between the
peak Pb1 (2850 cm.sup.-1) having the peak area "Sb" and the peak
Pa1 (1770 cm.sup.-1) having the peak area "Sa" was evaluated as a
peak area ratio or evaluation index "Sb/Sa."
[0321] The peak Pb1 (2850 cm.sup.-1) is a peak attributed to the
agent bar No. 11. Because a peak attributed to the photoconductor
also exists around the peak Pb1 (2850 cm.sup.-1) and overlaps with
the peak Pb1, a differential spectrum D between the IR spectrum C
(obtained after applying the protective agent to the
photoconductor) and the IR spectrum A for photoconductor not
applied with the protective agent is computed so that the peak area
of the peak Pb1 (2850 cm.sup.-1) attributed to the agent bar No. 11
is not effected by the peak area of the peak attributed to the
photoconductor, and then the peak area ratio or evaluation index
"Sb/Sa" is computed. When computing the differential spectrum D
(see FIG. 8), peak intensity was adjusted, such as increased or
decreased, as required. For example, a given coefficient is
multiplied to the absorbance of spectrum so as to set zero value
for the peak area of the peak at 1770 cm.sup.-1.
[0322] The evaluation index "Sb/Sa," which indicates an application
amount of the protective agent, increases as the application time
increases. For example, the evaluation index "Sb/Sa" was 0.19 at
the application time of 10 minutes, and the evaluation index
"Sb/Sa" was 0.38 at the application time of 360 minutes. Further,
an error of Sb/Sa was checked using five samples of the
photoconductor (1-5) applied with the protective agent for 360
minutes, wherein the five samples were adjacent each other in a
circumferential direction. When the Sb/Sa was computed with the
five samples, the Sb/Sa had an error of 8%. FIG. 13 shows
conditions of peak used for computing a peak area for each of
peaks, in which start and end point of background for computing a
peak area, and integration area of peak are included with
wavenumber information.
EXAMPLE 1-2
Phenyl Index
[0323] As for the IR spectrum obtained in Example 1-1, a peak area
ratio or evaluation index "Sb/Sa" was computed for the peak Pb2
(2920 cm.sup.-1) having a peak area Sb and the peak Pa2 (3040
cm.sup.-1) having a peak area Sa. The peak Pb2 (2920 cm.sup.-1) is
a peak attributed to the agent bar No. 11. Although a peak
attributed to the photoconductor also exists around the peak Pb2
(2920 cm.sup.-1) and overlaps with the peak Pb2, the peak Pb2 (2920
cm.sup.-1) has a peak area sufficiently greater than the peak area
of the peak attributed to the photoconductor. Accordingly, a step
of computing a differential spectrum of the IR spectrum C after
applying the protective agent to the photoconductor and the IR
spectrum A for the photoconductor not applied with the protective
agent was omitted, different from Example 1-1.
[0324] The evaluation index "Sb/Sa," which indicates an application
amount of the protective agent, increases as the application time
increases. For example, the evaluation index "Sb/Sa" was 10.3 at
the application time of 10 minutes, and the evaluation index
"Sb/Sa" was 23.2 at the application time of 360 minutes. Further,
an error of Sb/Sa was checked using five samples of the
photoconductor (1-5) applied with the protective agent for 360
minutes, wherein the five samples were adjacent each other in a
circumferential direction, and were different from the five samples
used for Example 1-1. When the Sb/Sa was computed with the five
samples, the Sb/Sa had an error of 12%.
EXAMPLE 1-3
[0325] The photoconductor, a brush roller No.3 (fiber having a
thickness of 20 denier, fiber density of 50,000 fibers per square
inch), and a urethane blade were assembled in a protective layer
setting unit (see FIG. 7). The agent bar No. 11 was pressed against
the brush with a spring force of 4.8 N to apply a protective agent
to the photoconductors (3-1) to (3-5). The photoconductor and the
brush roller rotated at a linear velocity of 125 mm/sec and 146
mm/sec, respectively.
[0326] The photoconductors (3-1) to (3-5) were applied with the
protective agent by changing an application time (3, 10, 40, 120,
360 minutes), and samples of each the photoconductors were prepared
after applying the protective agent. After applying the protective
agent, samples of the photoconductors (3-1) to (3-5) were analyzed
by FT-IR Avatar370 (manufactured by Thermo Electron Corporation,
Thunder Dome) under a condition of one time reflection, ATR prism
of Ge, incident angle of 45.degree. for IR spectrum analysis to
obtain the IR spectrum C (see FIG. 8). As for the IR spectrum C, a
peak area ratio or evaluation index "Sb/Sa" was computed for the
peak Pb1 (2850 cm.sup.-1) having a peak area Sb and the peak Pa1
(1770 cm.sup.-1) having a peak area Sa as similar to Example
1-1.
[0327] The evaluation index "Sb/Sa," which indicates an application
amount of the protective agent, increases as the application time
increases. For example, the evaluation index "Sb/Sa" was 0.06 at
the application time of 10 minutes, and the evaluation index
"Sb/Sa" was 0.71 at the application time of 360 minutes. Further,
an error of Sb/Sa was checked using five samples of the
photoconductor (3-5) applied with the protective agent for 360
minutes, wherein the five samples were adjacent each other in a
circumferential direction. When the Sb/Sa was computed with the
five samples, the Sb/Sa had an error of 11%.
EXAMPLE 1-4
[0328] As for the IR spectrum obtained in Example 1-3, a peak area
ratio or evaluation index "Sb/Sa" was computed for the peak Pb2
(2920 cm.sup.-1) having a peak area Sb and the peak Pa2 (3040
cm.sup.-1) having a peak area Sa as similar to Example 1-2.
[0329] The evaluation index "Sb/Sa," which indicates an application
amount of the protective agent, increases as the application time
increases. For example, the evaluation index "Sb/Sa" was 7.8 at the
application time of 10 minutes, and the evaluation index "Sb/Sa"
was 39.8 at the application time of 360 minutes. Further, an error
of Sb/Sa was checked using five samples of the photoconductor (3-5)
applied with the protective agent for 360 minutes, wherein the five
samples were adjacent each other in a circumferential direction,
and were different from the five samples used for Example 1-3. When
the Sb/Sa was computed with the five samples, the Sb/Sa had an
error of 7%.
(Comparison of ATR Prism and Incident Angle)
EXAMPLE 1-5
Change of ATR Prism
[0330] After applying the protective agent to the photoconductors
(1-1) to (1-5), another samples of the photoconductors (1-1) to
(1-5) were analyzed by FT-IR Avatar370 (manufactured by Thermo
Electron Corporation, Smart Orbit) under a condition of one time
reflection, ATR prism of diamond, incident angle of 45.degree. for
IR spectrum analysis to obtain the IR spectrum C (see FIG. 8) as
similar to Example 1-1.
[0331] Although the peak Pa1 (1770 cm.sup.-1) has a sufficient peak
area, the peak area of the peak Pa1 changed little even if an
application time is varied, and the peak Pb1 (2850 cm.sup.-1)
attributed to the protective agent had a too small area. The peak
area for the peak Pb1 (2850 cm.sup.-1) was computed to obtain the
evaluation index "Sb/Sa," which indicates an application amount of
the protective agent. Although the "Sb/Sa" increases as the
application time increases, the increase amount of the "Sb/Sa" was
too small. Further, an error of Sb/Sa was checked using five
samples of the photoconductor (1-5) applied with the protective
agent for 360 minutes, wherein the five samples were adjacent each
other in a circumferential direction. When the Sb/Sa was computed
with the five samples, the Sb/Sa had an error of 35%.
EXAMPLE 1-6
Change of Incident Angle
[0332] After applying the protective agent in Example 1-3, another
samples of the photoconductors (3-1) to (3-5) were analyzed by
FT-IR Avatar370 (manufactured by Thermo Electron Corporation,
Seagull) under a condition of one time reflection, ATR prism of Ge,
incident angle of 85.degree. for IR spectrum analysis to obtain the
IR spectrum C (see FIG. 8). In Example 1-6,the peak area of peak
Pb1 and the peak Pa1 was checked. Although the peak area of the
peak Pb1 (2850 cm.sup.-1) attributed to the protective agent
increases as the application time increases, the increase amount of
the peak area of the peak Pb1 was too small. The peak area of peak
Pa1 (1770 cm.sup.-1) had a too small area. The evaluation index
"Sb/Sa," which indicates an application amount of the protective
agent, increases as the application time increases, but the
increase amount of the "Sb/Sa" was too small. Further, an error of
Sb/Sa was checked using five samples of the photoconductor (3-5)
applied with the protective agent for 360 minutes, wherein the five
samples were adjacent each other in a circumferential direction.
When the Sb/Sa was computed with the five samples, the Sb/Sa had an
error of 32%.
EXAMPLE 1-7
Change of Incident Angle
[0333] After applying the protective agent in Example 1-1, another
samples of the photoconductors (1-1) to (1-5) were analyzed by
FT-IR Avatar370 (manufactured by Thermo Electron Corporation, GATR)
under a condition of one time reflection, ATR prism of Ge, incident
angle of 30.degree. for IR spectrum analysis to obtain the IR
spectrum C (see FIG. 8). A fixing screw, an accessory of the GATR,
was used to fix a sample for measurement by rotating the fixing
screw. The fixing screw was rotated for 1/2 rotation from a point
when the peak was started to be detected, and fixed at such 1/2
rotation position to sufficiently hold the sample against the ATR
prism to conduct measurement of IR spectrum of the sample. As
similar to Example 1-1, the peak Pa1 (1770 cm.sup.-1) and the peak
Pb1 (2850 cm.sup.-1) were clearly detected. The evaluation index
"Sb/Sa," which indicates an application amount of the protective
agent, increases as the application time increases, but the
increase amount of the "Sb/Sa" was small. Further, an error of
Sb/Sa was checked using five samples of the photoconductor (1-5)
applied with the protective agent for 360 minutes, wherein the five
samples were adjacent each other in a circumferential direction.
When the Sb/Sa was computed with the five samples, the Sb/Sa had an
error of 25%.
Agent Bar No. 12
[0334] FT115 (synthesize wax manufactured by Nippon Seiro Co.,Ltd.)
of 60 weight part and trisorbitan stearate (HLB: 1.5) of 25 weight
part, and normal paraffin (average molecular weight 640) of 15
weight part were placed in a glass vessel having a cap, and were
agitated and melted at a temperature of 180 degrees Celcius using a
hot stirrer. Then, the melted protective agent was poured in an
internal space of an aluminum metal mold, having a size of 12
mm.times.8 mm.times.350 mm, heated to 115 degrees Celcius in
advance. After cooling to 90 degrees Celcius on a wooden table, the
aluminum metal mold was cooled to 40 degrees Celcius on an aluminum
table. Then, the solidified product was removed from the mold, and
cooled to an ambient temperature while placing a weight on the
product for preventing a warping. After that, an agent bar No. 12
having a size of 7 mm.times.8 mm.times.310 mm was prepared by
cutting some portion of the product. The agent bar No. 12 was
attached with a double face tape and fixed to a metal
supporter.
EXAMPLES 1-8 TO 1-12
[0335] Protective layer setting units were evaluated using a peak
area ratio or evaluation index "Sb/Sa" using the peak Pb1 (2850
cm.sup.-1) having the peak area Sb and the peak Pa1 (1770
cm.sup.-1) having the Sa by setting a threshold value for the
evaluation index "Sb/Sa." Specifically, the protective layer
setting unit was evaluated as "acceptable" when the Sb/Sa at the
10-minute application time of the protective agent was 0.03 or
more, and when the Sb/Sa at the 360-minute application time of the
protective agent was 0.90 or less. Examples 1-8 to 1-12 were
evaluated as below.
EXAMPLE 1-8
Protective Layer Setting Unit (11)
[0336] The photoconductors (8-1) and (8-2) were applied with the
protective agent by changing an application time (10, 360 minutes).
Specifically, the photoconductors (8-1) and (8-2), a brush roller
No. 2 (fiber having a thickness of 10 denier, fiber density of
50,000 fibers per square inch), and a urethane blade were assembled
in a protective layer setting unit (see FIG. 7). The agent bar No.
11 was pressed against the brush with a spring force of 4.8 N to
apply a protective agent to the photoconductor drum for 10 minutes
and 360 minutes. The photoconductor drum and the brush roller
rotated at a linear velocity of 125 mm/sec and 146 mm/sec,
respectively. After applying the protective agent, samples of the
photoconductors (8-1) to (8-2) were analyzed by FT-IR Avatar370
(manufactured by Thermo Electron Corporation, Thunder Dome) under a
condition of one time reflection, ATR prism of Ge, incident angle
of 45.degree. for IR spectrum analysis to obtain the IR spectrum C
(see FIG. 8). As similar to Example 1-1, the Sb/Sa was computed to
obtain Sb/Sa=0.17 at the 10-minute application time, and Sb/Sa=0.36
at the 360-minute application time, by which the protective layer
setting unit (11) was evaluated as "acceptable," which is indicated
by a circle in FIG. 15.
EXAMPLE 1-9
Protective Layer Setting Unit (12)
[0337] The photoconductors (9-1) and (9-2), a brush roller No.3
(fiber having a thickness of 20 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 12
was pressed against the brush with a spring force of 4.8 N to apply
a protective agent to the photoconductor drum for 10 minutes and
360 minutes. The photoconductor drum and the brush roller rotated
at a linear velocity of 125 mm/sec and 146 mm/sec, respectively.
After applying the protective agent, samples of the photoconductors
(9-1) and (9-2) were analyzed by FT-IR Avatar370 (manufactured by
Thermo Electron Corporation, Thunder Dome) under a condition of one
time reflection, ATR prism of Ge, incident angle of 45.degree. for
IR spectrum analysis to obtain the IR spectrum C (see FIG. 8). As
similar to Example 1-1, the Sb/Sa was computed to obtain Sb/Sa=0.06
at the 10-minute application time, and Sb/Sa=0.82 at the 360-minute
application time, by which the protective layer setting unit (12)
was evaluated as "acceptable," which is indicated by a circle in
FIG. 15.
EXAMPLE 1-10
Protective Layer Setting Unit (13)
[0338] The photoconductors (10-1) and (10-2), a brush roller No. 1
(fiber having a thickness of 10 denier, fiber density of 30,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 12
was pressed against the brush with a spring force of 2 N to apply a
protective agent to the photoconductor drum for 10 minutes and 360
minutes. The photoconductor drum and the brush roller rotated at a
linear velocity of 125 mm/sec and 146 mm/sec, respectively. After
applying the protective agent, samples of the photoconductors
(10-1) and (10-2) were analyzed by FT-IR Avatar370 (manufactured by
Thermo Electron Corporation, Thunder Dome) under a condition of one
time reflection, ATR prism of Ge, incident angle of 45.degree. for
IR spectrum analysis to obtain the IR spectrum C (see FIG. 8). As
similar to Example 1-1, the Sb/Sa was computed to obtain Sb/Sa=0.02
at the 10-minute application time, and Sb/Sa=0.23 at the 360-minute
application time, by which the protective layer setting unit (13)
was evaluated as "not acceptable," which is indicated by a cross in
FIG. 15.
EXAMPLE 1-11
Protective Layer Setting Unit (14)
[0339] The photoconductors (11-1) and (11-2), a brush roller No. 3
(fiber having a thickness of 20 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 11
was pressed against the brush with a spring force of 2 N to apply a
protective agent to the photoconductor drum for 10 minutes and 360
minutes. The photoconductor drum and the brush roller rotated at a
linear velocity of 125 mm/sec and 146 mm/sec, respectively. After
applying the protective agent, samples of the photoconductors
(11-1) and (11-2) were analyzed by FT-IR Avatar370 (manufactured by
Thermo Electron Corporation, Thunder Dome) under a condition of one
time reflection, ATR prism of Ge, incident angle of 45.degree. for
IR spectrum analysis to obtain the IR spectrum C (see FIG. 8). As
similar to Example 1-1, the Sb/Sa was computed to obtain Sb/Sa=0.02
at the 10-minute application time, and Sb/Sa=0.43 at the 360-minute
application time, by which the protective layer setting unit (14)
was evaluated as "not acceptable," which is indicated by a cross in
FIG. 15.
EXAMPLE 1-12
Protective Layer Setting Unit (15)
[0340] The photoconductors (12-1) and (12-2), a brush roller No. 3
(fiber having a thickness of 20 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 12
was pressed against the brush with a spring force of 4.8 N to apply
a protective agent to the photoconductor drum for 10 minutes and
360 minutes. The photoconductor drum and the brush roller rotated
at a linear velocity of 125 mm/sec and 146 mm/sec, respectively.
After applying the protective agent, samples of the photoconductors
(12-1) and (12-2) were analyzed by FT-IR Avatar370 (manufactured by
Thermo Electron Corporation, Thunder Dome) under a condition of one
time reflection, ATR prism of Ge, incident angle of 45.degree. for
IR spectrum analysis to obtain the IR spectrum C (see FIG. 8). As
similar to Example 1-1, the Sb/Sa was computed to obtain Sb/Sa=0.12
at the 10-minute application time, and Sb/Sa=1.1 at the 360-minute
application time, by which the protective layer setting unit (15)
was evaluated as "not acceptable," which is indicated by a cross in
FIG. 15.
EXAMPLES 1-13 TO 1-17
[0341] Protective layer setting units were evaluated using a peak
area ratio or evaluation index "Sb/Sa" using the peak Pb2 (2920
cm.sup.-1) having the peak area Sb and the peak Pa2 (3040
cm.sup.-1) having the Sa by setting a threshold value for the
evaluation index "Sb/Sa." Specifically, the protective layer
setting unit was evaluated as "acceptable" when the Sb/Sa at the
10-minute application time of the protective agent was 6.5 or more,
and when the Sb/Sa at the 360-minute application time of the
protective agent was 44.0 or less. Examples 1-13 to 1-17 were
evaluated as below.
EXAMPLE 1-13
Protective Layer Setting Unit (11)
[0342] As for the IR spectrum obtained in Example 1-8, the Sb/Sa
was computed using the peak Pb2 (2920 cm.sup.-1) having the peak
area Sb and the peak Pa2 (3040 cm.sup.-1) having the peak area Sa.
The Sb/Sa was computed to obtain Sb/Sa=12.1 at the 10-minute
application time, and Sb/Sa=22.8 at the 360-minute application
time, by which the protective layer setting unit (11) was evaluated
as "acceptable," which is indicated by a circle in FIG. 15.
EXAMPLE 1-14
Of Protective Layer Setting Unit (12)
[0343] As for the IR spectrum obtained in Example 1-9, the Sb/Sa
was computed using the peak Pb2 (2920 cm.sup.-1) having the peak
area Sb and the peak Pa2 (3040 cm.sup.-1) having the peak area Sa.
The Sb/Sa was computed to obtain Sb/Sa=8.0 at the 10-minute
application time, and Sb/Sa=43.3 at the 360-minute application
time, by which the protective layer setting unit (12) was evaluated
as "acceptable," which is indicated by a circle in FIG. 15.
EXAMPLE 1-15
Protective Layer Setting Unit (13)
[0344] As for the IR spectrum obtained in Example 1-10, the Sb/Sa
was computed using the peak Pb2 (2920 cm.sup.-1) having the peak
area Sb and the peak Pa2 (3040 cm.sup.-1) having the peak area Sa.
The Sb/Sa was computed to obtain Sb/Sa=6.0 at the 10-minute
application time, and Sb/Sa=18.7 at the 360-minute application
time, by which the protective layer setting unit (13) was evaluated
as "not acceptable," which is indicated by a cross in FIG. 15.
EXAMPLE 1-16
Protective Layer Setting Unit (14)
[0345] As for the IR spectrum obtained in Example 1-11, the Sb/Sa
was computed using the peak Pb2 (2920 cm.sup.-1) having the peak
area Sb and the peak Pa2 (3040 cm.sup.-1) having the peak area Sa.
The Sb/Sa was computed to obtain Sb/Sa=5.8 at the 10-minute
application time, and Sb/Sa=27.6 at the 360-minute application
time, by which the protective layer setting unit (14) was evaluated
as "not acceptable," which is indicated by a cross in FIG. 15.
EXAMPLE 1-17
Protective Layer Setting Unit (15)
[0346] As for the IR spectrum obtained in Example 1-12, the Sb/Sa
was computed using the peak Pb2 (2920 cm.sup.-1) having the peak
area Sb and the peak Pa2 (3040 cm.sup.-1) having the peak area Sa.
The Sb/Sa was computed to obtain Sb/Sa=10.3 at the 10-minute
application time, and Sb/Sa=73.2 at the 360-minute application
time, by which the protective layer setting unit (15) was evaluated
as "not acceptable," which is indicated by a cross in FIG. 15.
EXAMPLE 1-18
[0347] When evaluating performance of an image forming apparatus,
the photoconductors (8-2) and (9-2) were respectively assembled to
black and cyan image forming units of IPSIO CX400, a tandem type
color image forming apparatus produced by Ricoh Company, Ltd. The
photoconductor (8-2) was used for Example 1-8 and the
photoconductor (9-2) was used for Example 1-9. A charge roller was
pressed to the photoconductor (8-2) using an agent biasing spring
of the protective layer setting unit (11), and a charge roller was
pressed to the photoconductor (9-2) using an agent biasing spring
of the protective layer setting unit (12). The black photoconductor
unit (or black unit) was used under a condition of the protective
layer setting unit (11) having brush roller No. 2 and urethane
blade. The cyan photoconductor unit (or cyan unit) was used under a
condition of the protective layer setting unit (15) having brush
roller No. 3 and urethane blade. The charge roller was disposed
above the photoconductor drum, the photoconductor drum rotated at a
linear velocity of 125 mm/sec, a superimposed voltage having a
direct-current voltage of -600 V and an alternating-current voltage
having a frequency 1450 Hz and an amplitude of 1100 V was applied
between the photoconductor drum and the charge roller. The
photoconductors (8-2) and (9-2) were supplied with the protective
agent using the protective layer setting units (11) and (15),
respectively.
[0348] FIG. 11 illustrates evaluation image patterns used for the
experiment. As shown in FIG. 12, striped halftone images of each
colors of black, cyan, magenta, and yellow are formed side by side.
When evaluating performance of an image forming apparatus used for
the experiment, such evaluation image pattern was used as a test
image, and the image forming apparatus was operated to copy such
test image on a greater number of sheets. The copied image quality
was checked based on image evaluation criteria. When the black unit
and the cyan unit were operated to produce one-by-one halftone
image of A4 size shown in FIG. 12 for five sheets to evaluate image
quality, it was evaluated that the black unit and the cyan unit
produced higher quality image, as indicated by a circle in FIG. 16.
Further, the black unit and the cyan unit were operated to produce
one-by-one halftone image of A4 size shown in FIG. 12 for 70,000
sheets to evaluate image quality, in which five sheets were printed
as one set until 70,000 sheets were printed. In this case, the
black unit produced higher quality image (as indicated by a circle
in FIG. 16). but the cyan unit produced images having a white
streak (as indicated by a cross in FIG. 16).
[0349] With the results obtained by above described experiment, a
protective layer setting unit can be evaluated as "acceptable" or
"not acceptable" by setting threshold values as described with
Examples 1-8 to 1-12 and Examples 1-13 to 1-17.
[0350] FIGS. 14 to 17 show conditions for protective agent bars,
protective layer setting units, ATR analysis, and results of ATR
analysis and image evaluation for Examples 1-1 to 1-18.
[0351] A description is given to experiment and its results in
detail using a process cartridge prepared according to an exemplary
embodiment. It should be noted that following Example 2 used in the
experiment are just exemplary, and other configuration can be
devised.
[0352] FIG. 7 illustrates a schematic configuration of the
protective layer setting unit 2 used in the experiment, in which
the blade of the protective layer setting unit contacts the
photoconductor surface in a counter direction. The photoconductor
drum used in the experiment was manufactured as below.
Photoconductor Drum
[0353] An aluminum drum (conductive supporter) having a diameter of
30 mm was coated with an under layer, a charge generation layer, a
charge transport layer, and a surface layer in this order, and
dried to form the photoconductor drum having an under layer of 3.6
.mu.m thickness, a charge generation layer of about 0.14 .mu.m
thickness, a charge transport layer of 23 .mu.m thickness, and a
surface layer of about 3.5 .mu.m thickness. The surface layer was
coated using a spray method, and other layers were coated using a
dipping method. The surface layer includes following materials.
[0354] (Surface Layer) [0355] Z-type polycarbonate: 10 parts [0356]
triphenylamine compound (see structural formula 1): 7 parts [0357]
fine alumina particles (particle diameter of 0.3 .mu.m): 5 parts
[0358] tetrahydrofuran: 400 parts [0359] cyclohexanone: 150
parts
##STR00001##
[0359] Agent bar No. 21
[0360] FT115 (synthesize wax manufactured by Nippon Seiro Co.,Ltd.)
of 85 weight part, TOPAS-TM (manufactured by manufactured by
Ticona) of 10 weight part, and trisorbitan stearate (HLB: 1.5) of 5
weight part were placed in a glass vessel having a cap, and were
agitated and melted at a temperature of 160-250 degrees Celcius
using a hot stirrer. Then, the melted protective agent was poured
in an internal space of an aluminum metal mold, having a size of 12
mm.times.8 mm.times.350 mm, heated to 115 degrees Celcius in
advance. After cooling to 88 degrees Celcius on a wooden table, the
aluminum metal mold was cooled to 40 degrees Celcius on an aluminum
table. Then, the solidified product was removed from the mold, and
then cooled to an ambient temperature while placing a weight on the
product for preventing warping. After that, an agent bar No. 21
having a size of 7 mm.times.8 mm.times.310 mm was prepared by
cutting some portion of the product. The agent bar No. 21 was
attached with a double face tape and fixed to a metal
supporter.
[0361] Samples of the photoconductor and the agent bar No. 21 were
analyzed by FT-IR Avatar370 (manufactured by Thermo Electron
Corporation, Thunder Dome) under a condition of one time
reflection, ATR prism of Ge, incident angle of 45.degree. for IR
spectrum analysis to obtain spectrum (or absorbance spectrum),
which was similar to the IR spectrum A and B shown in FIG. 8. In
the IR spectrum A of the photoconductor, the peak Pa1 attributed to
polycarbonate bond is observed at 1770 cm.sup.-1. In the IR
spectrum B of the agent bar No. 21, the peak Pb1 (2850 cm.sup.-1)
and the peak Pb2 (2920 cm.sup.-1) attributed to methylene group are
observed. When the photoconductor was measured by the ATR, a
measurement sample having 1 cm.times.1 cm size was cut from an
aluminum base of the photoconductor.
EXAMPLE 2-1
Protective Layer Setting Unit (21)
[0362] The photoconductors (1-1) and (1-2), a brush roller No. 2
(fiber having a thickness of 10 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 21
was pressed against the brush with a spring force of 4 N to apply a
protective agent to the photoconductor. The photoconductor and the
brush roller rotated at a linear velocity of 125 mm/sec and 146
mm/sec, respectively. After applying the protective agent for 150
minutes to photoconductor (1-2) using the protective layer setting
unit (21), a sample of the photoconductor was sliced using a
ultramicrotome and TEM (transmission electron microscope)
observation was conducted, and it was found that the layer
thickness of protective agent was 50 nm to 85 nm based on TEM
photo.
[0363] The photoconductors (1-1) and (1-2) were applied with the
protective agent by changing an application time (5, 150 minutes),
and samples of each the photoconductors were prepared after
applying the protective agent. After applying the protective agent,
samples of the photoconductors (1-1) and (1-2) were analyzed by
FT-IR Avatar370 (manufactured by Thermo Electron Corporation,
Thunder Dome) under a condition of one time reflection, ATR prism
of Ge, incident angle of 45.degree. for IR spectrum analysis to
obtain the IR spectrum (or absorbance spectrum), similar to the IR
spectrum C shown in FIG. 8, when the application time was 150
minutes.
[0364] Based on the IR spectrum C, a peak area ratio between the
the peak Pb1 (2850 cm.sup.-1) having the peak area "Sb1" and the
peak Pa1 (1770 cm.sup.-1) having the peak area "Sa1" was evaluated
as a peak area ratio or evaluation index "Sb1/Sa1." The peak Pb1
(2850 cm.sup.-1) is a peak attributed to the agent bar No.21.
Because a peak attributed to the photoconductor also exists around
the peak Pb1 (2850 cm.sup.-1) and overlaps with the peak Pb1, a
differential spectrum D between the IR spectrum C (obtained after
applying the protective agent to the photoconductor) and the IR
spectrum A for photoconductor not applied with the protective agent
is computed so that the peak area of the peak Pb1 (2850 cm.sup.-1)
attributed to the agent bar No. 21 is not effected by the peak area
of the peak attributed to the photoconductor, and then the peak
area ratio or evalution index "Sb1/Sa1" is computed. When computing
the differential spectrum D (see FIG. 8), peak intensity was
adjusted, such as increased or decreased, as required. For example,
a given coefficient is multiplied to the absorbance of spectrum so
as to set zero value for the peak area of the peak at 1770
cm.sup.-1. The evaluation index "Sb1/Sa1," which indicates an
application amount of the protective agent, increases as the
application time increases. For example, the evaluation index
"Sb1/Sa1" was 0.082 at the application time of 5 minutes, and the
evaluation index "Sb1/Sa1" was 0.23 at the application time of 150
minutes.
[0365] FIG. 18 shows conditions of peak used for computing a peak
area for each of peaks, in which start and end point of background
for computing a peak area, and integration area of peak are
included with wavenumber information.
EXAMPLE 2-2
Protective Layer Setting Unit (22)
[0366] The photoconductor drums (2-1) and (2-2), a brush roller No.
3 (fiber having a thickness of 20 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 21
was pressed against the brush with a spring force of 4 N to apply a
protective agent to the photoconductors for 5 minutes and 150
minutes, respectively. The photoconductor drum and the brush roller
rotated at a linear velocity of 125 mm/sec and 146 mm/sec,
respectively. After applying the protective agent, samples of the
photoconductors (2-1) and (2-2) were analyzed by FT-IR Avatar370
(manufactured by Thermo Electron Corporation, Thunder Dome) under a
condition of one time reflection, ATR prism of Ge, incident angle
of 450 for IR spectrum analysis to obtain the IR spectrum C (see
FIG. 8). As similar to Example 2-1, the Sb1/Sa1 was computed to
obtain Sb1/Sa1=0.044 at the 5-minute application time, and
Sb1/Sa1=0.45 at the 150-minute application time.
Agent bar No. 22
[0367] FT115 (synthesize wax manufactured by Nippon Seiro Co.,Ltd.)
of 55 weight part, trisorbitan stearate (HLB: 1.5) of 20 weight
part, and normal paraffin (average molecular weight 640) of 25
weight part were placed in a glass vessel having a cap, and were
agitated and melted at a temperature of 180 degrees Celcius using a
hot stirrer. Then, the melted protective agent was poured in an
internal space of an aluminum metal mold, having a size of 12
mm.times.8 mm.times.350 mm, heated to 115 degrees Celcius in
advance. After cooling to 90 degrees Celcius on a wooden table, the
aluminum metal mold was cooled to 40 degrees Celcius on an aluminum
table. Then, the solidified product was removed from the mold, and
then cooled to an ambient temperature while placing a weight on the
product for preventing warping. After that, an agent bar No. 21
having a size of 7 mm.times.8 mm.times.310 mm was prepared by
cutting some portion of the product. The agent bar No. 22 was
attached with a double face tape and fixed to a metal
supporter.
COMPARATIVE EXAMPLE 2-1
Protective Layer Setting Unit (23)
[0368] The photoconductor drums (3-1) and (3-2), a brush roller No.
1 (fiber having a thickness of 10 denier, fiber density of 3,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 21
was pressed against the brush with a spring force of 1.8 N to apply
a protective agent to the photoconductors for 5 minutes and 150
minutes, respectively. The photoconductor and the brush roller
rotated at a linear velocity of 125 mm/sec and 146 mm/sec,
respectively. After applying the protective agent, samples of the
photoconductors (3-1) and (3-2) were analyzed by FT-IR Avatar370
(manufactured by Thermo Electron Corporation, Thunder Dome) under a
condition of one time reflection, ATR prism of Ge, incident angle
of 45.degree. for IR spectrum analysis to obtain the IR spectrum C
(see FIG. 8). As similar to Example 2-1, the Sb1/Sa1 was computed
to obtain Sb1/Sa1=0.022 at the 5-minute application time, and
Sb1/Sa1=0.13 at the 150-minute application time.
COMPARATIVE EXAMPLE 2-2
Protective Layer Setting Unit (24)
[0369] The photoconductor drums (4-1) and (4-2), a brush roller No.
3 (fiber having a thickness of 20 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 22
was pressed against the brush with a spring force of 6 N to apply a
protective agent to the photoconductors for 5 minutes and 150
minutes, respectively. The photoconductor and the brush roller
rotated at a linear velocity of 125 mm/sec and 146 mm/sec,
respectively. After applying the protective agent, samples of the
photoconductors (4-1) and (4-2) were analyzed by FT-IR Avatar370
(manufactured by Thermo Electron Corporation, Thunder Dome) under a
condition of one time reflection, ATR prism of Ge, incident angle
of 45.degree. for IR spectrum analysis to obtain the IR spectrum C
(see FIG. 8). As similar to Example 2-1, the Sb1/Sa1 was computed
to obtain Sb1/Sa1=0.14 at the 5-minute application time, and
Sb1/Sa1=0.88 at the 150-minute application time.
COMPARATIVE EXAMPLE 2-3
Protective Layer Setting Unit (25)
[0370] The photoconductor drums (5-1) and (5-2), a brush roller No.
3 (fiber having a thickness of 20 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 22
was pressed against the brush with a spring force of 3 N to apply a
protective agent to the photoconductors for 5 minutes and 150
minutes, respectively. The photoconductor and the brush roller
rotated at a linear velocity of 125 mm/sec and 146 mm/sec,
respectively. After applying the protective agent, samples of the
photoconductors (5-1) and (5-2) were analyzed by FT-IR Avatar370
(manufactured by Thermo Electron Corporation, Thunder Dome) under a
condition of one time reflection, ATR prism of Ge, incident angle
of 45.degree. for IR spectrum analysis to obtain the IR spectrum C
(see FIG. 8). As similar to Example 2-1, the Sb1/Sa1 was computed
to obtain Sb1/Sa1=0.032 at the 5-minute application time, and
Sb1/Sa1=0.32 at the 150-minute application time.
[Evaluation of Image Quality]
[0371] When evaluating performance of an image forming apparatus,
IPSIO CX400, a tandem type color image forming apparatus produced
by Ricoh Company, Ltd was used. As for a black process cartridge
(1), a protective layer setting unit having a similar configuration
of the protective layer setting unit (21), used in Example 2-1, was
assembled, wherein the protective layer setting unit includes a
protective agent bar, a brush, and a biasing spring. As for a cyan
process cartridge (1), a protective layer setting unit having a
similar configuration of the protective layer setting unit (23),
used in Comparative Example 2-1, was assembled. As for a magenta
process cartridge (1), a protective layer setting unit having a
similar configuration of the protective layer setting unit (24),
used in Comparative Example 2-2, was assembled. The process
cartridges were installed in IPSIO CX400. A charge roller was
disposed above the photoconductor drum, the photoconductor drum
rotated at a linear velocity of 125 mm/sec, a superimposed voltage
having a direct-current voltage of -600 V and an
alternating-current voltage having a frequency 1450 Hz and an
amplitude of 1100 V was applied between the photoconductor drum and
the charge roller. Each of the process cartridges was installed
with a new photoconductor, which is similar to photoconductors used
in Examples 2-1 to 2-3 and Comparative Examples 2-1 and 2-2.
[0372] When the black, cyan, and magenta process cartridges were
operated to produce one-by-one halftone image of A4 size shown in
FIG. 12 for five sheets to evaluate image quality, it was evaluated
that the black, cyan, and magenta process cartridges produced
higher quality image, as indicated by a circle in FIG. 21.
[0373] Further, the black, cyan, and magenta process cartridges
were operated to produce one-by-one halftone image of A4 size shown
in FIG. 12 for 60,000 sheets to evaluate image quality, in which
five sheets were printed as one set until 60,000 sheets were
printed. In this case, the black process cartridge produced higher
quality image (as indicated by a circle in FIG. 21), but the cyan
process cartridge produced images having a white streak and the
magenta process cartridge produced images having a black streak,
which are not preferable image quality (as indicated by a cross in
FIG. 21).
[0374] Further, another evaluation of image quality was similarly
conducted using the protective layer setting units used in Example
2-2 and Comparative Example 2-3 and process cartridges having such
protective layer setting units. When evaluating performance of an
image forming apparatus, IPSIO CX400, a tandem type color image
forming apparatus produced by Ricoh Company, Ltd was used. As for a
black process cartridge (2), a protective layer setting unit having
a similar configuration of the protective layer setting unit (22),
used in Example 2-2, was assembled, wherein the protective layer
setting unit includes a protective agent bar, a brush, and a
biasing spring. As for a cyan process cartridge (2), a protective
layer setting unit having a similar configuration of the protective
layer setting unit (25), used in Comparative Example 2-3, was
assembled. The process cartridges were installed in IPSIO CX400. A
charge roller was disposed above the photoconductor drum, the
photoconductor drum rotated at a linear velocity of 125 mm/sec, a
superimposed voltage having a direct-current voltage of -600 V and
an alternating-current voltage having a frequency 1450 Hz and an
amplitude of 1100 V was applied between the photoconductor drum and
the charge roller. Each of the process cartridges was installed
with a new photoconductor, which is similar to photoconductors used
in Examples 2-1 to 2-3 and Comparative Examples 2-1 and 2-2.
[0375] When the black, and cyan process cartridges were operated to
produce one-by-one halftone image of A4 size shown in FIG. 12 for
five sheets to evaluate image quality, it was evaluated that the
black and cyan process cartridges produced higher quality image, as
indicated by a circle in FIG. 21. Further, the black and cyan
process cartridges were operated to produce one-by-one halftone
image of A4 size shown in FIG. 12 for 60,000 sheets to evaluate
image quality, in which five sheets were printed as one set until
60,000 sheets were printed. In this case, the black process
cartridge produced higher quality image (as indicated by a circle
in FIG. 21), but the cyan process cartridge produced images having
a white streak, which is not preferable image quality (as indicated
by a cross in FIG. 21).
[0376] FIGS. 19 to 22 show conditions for protective agent bars,
protective layer setting units, ATR analysis, and results of ATR
analysis and image evaluation for Examples 2 and Comparative
Examples 2.
[0377] A description is now given to experiment and its results in
detail using a process cartridge prepared according to an exemplary
embodiment. It should be noted that following Example 3 used in the
experiment are just exemplary, and other configuration can be
devised.
[0378] FIG. 7 illustrates a schematic configuration of the
protective layer setting unit 2 used in the experiment. The
photoconductor drum used in the experiment was manufactured as
below.
Photoconductor Drum
[0379] An aluminum drum (conductive supporter) having a diameter of
30 mm was coated with an under layer, a charge generation layer, a
charge transport layer, and a surface layer in this order, and
dried to form the photoconductor drum having an under layer of 3.6
.mu.m thickness, a charge generation layer of about 0.14 .mu.m
thickness, a charge transport layer of 23 .mu.m thickness, and a
surface layer of about 3.5 .mu.m thickness. The surface layer was
coated using a spray method, and other layers were coated using a
dipping method. The surface layer includes following material.
[0380] (surface layer) [0381] Z-type polycarbonate: 10 parts [0382]
triphenylamine compound (the aforementioned structural formula 1):
7 parts [0383] fine alumina particles (particle diameter of 0.3
.mu.m): 5 parts [0384] tetrahydrofuran: 400 parts [0385]
cyclohexanone: 150 parts
Agent bar No. 31
[0386] FT115 (synthesize wax manufactured by Nippon Seiro Co.,Ltd.)
of 90 weight part, TOPAS-TM (manufactured by manufactured by
Ticona) of 5 weight part, and trisorbitan stearate (HLB: 1.5) of 5
weight part were placed in a glass vessel having a cap, and were
agitated and melted at a temperature of 160-250 degrees Celcius
using a hot stirrer. Then, the melted protective agent was poured
in an internal space of an aluminum metal mold, having a size of 12
mm.times.8 mm.times.350 mm, heated to 115 degrees Celcius in
advance. After cooling to 88 degrees Celcius on a wooden table, the
aluminum metal mold was cooled to 40 degrees Celcius on an aluminum
table. Then, the solidified product was removed from the mold, and
then cooled to an ambient temperature while placing a weight on the
product for preventing warping. After that, a protective agent bar
No. 31 having a size of 7 mm.times.8 mm.times.310 mm was prepared
by cutting some portion of the product. The protective agent bar
No. 31 was attached with a double face tape and fixed to a metal
supporter.
[0387] Samples of the photoconductor and the agent bar No. 31 were
analyzed by FT-IR Avatar370 (manufactured by Thermo Electron
Corporation, Thunder Dome) under a condition of one time
reflection, ATR prism of Ge, incident angle of 45.degree. for IR
spectrum analysis to obtain spectrum (or absorbance spectrum),
which was similar to the IR spectrum A and B shown in FIG. 8. In
the IR spectrum A of the photoconductor, the peak Pa2 attributed to
phenyl group is observed at 3040 cm.sup.-1. In the IR spectrum B of
the agent bar No. 31, the peak Pb1 (2850 cm.sup.-1) and peak Pb2
(2920 cm.sup.-1) attributed to methylene group are observed. When
the photoconductor was measured by the ATR, a measurement sample
having 1 cm.times.1 cm size was cut from an aluminum base of the
photoconductor.
EXAMPLE 3-1
Protective Layer Setting Unit (31)
[0388] The photoconductor drums (1-1) and (1-2), a brush roller No.
2 (fiber having a thickness of 10 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The protective agent
bar No. 31 was pressed against the brush with a spring force of 4.8
N to apply a protective agent to the photoconductors. The
photoconductor drum and the brush roller rotated at a linear
velocity of 125 mm/sec and 146 mm/sec, respectively. After applying
the protective agent for 120 minutes to photoconductor (1-2) using
the protective layer setting unit (31), a sample of the
photoconductor was sliced using a ultramicrotome and TEM
(transmission electron microscope) observation was conducted, and
it was found that the layer thickness of protective agent was 25 nm
to 70 nm based on TEM photo.
[0389] The photoconductors (1-1) and (1-2) were applied with the
protective agent by changing an application time (5, 120 minutes),
and samples of each the photoconductors were prepared after
applying the protective agent. After applying the protective agent,
samples of the photoconductors (1-1) and (1-2) were analyzed by
FT-IR Avatar370 (manufactured by Thermo Electron Corporation,
Thunder Dome) under a condition of one time reflection, ATR prism
of Ge, incident angle of 45.degree. for IR spectrum analysis to
obtain the IR spectrum (or absorbance spectrum), similar to the IR
spectrum C shown in FIG. 8, when the application time was 120
minutes. Based on the IR spectrum C, a peak area ratio between the
the peak Pb2 (2920 cm.sup.-1) having the peak area "Sb2" and the
peak Pa2 (3040 cm.sup.-1) having the peak area "Sa2" was evaluated
as a peak area ratio or evaluation index "Sb2/Sa2." The peak Pb2
(2920 cm.sup.-1) is a peak attributed to the agent bar No. 31.
Although a peak attributed to the photoconductor also exists around
the peak Pb2 (2920 cm.sup.-1) and overlaps with the peak Pb2, the
peak Pb2 (2920 cm.sup.-1) has a peak area sufficiently greater than
the peak area of the peak attributed to the photoconductor.
Accordingly, a step of computing a differential spectrum of the IR
spectrum C after applying the protective agent to the
photoconductor and the IR spectrum A for the photoconductor not
applied with the protective agent was omitted. The evaluation index
"Sb2/Sa2," which indicates an application amount of the protective
agent was 9.8 at the application time of 15 minutes, and the
evaluation index "Sb2/Sa2" was 13.5 at the application time of 120
minutes. FIG. 23 shows conditions of peak used for computing a peak
area for each of peaks, in which start and end point of background
for computing a peak area, and integration area of peak are
included with wavenumber information.
EXAMPLE 3-2
Protective Layer Setting Unit (32)
[0390] The photoconductor drums (2-1) and (2-2), a brush roller No.
3 (fiber having a thickness of 20 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 11
was pressed against the brush with a spring force of 4.8 N to apply
a protective agent to the photoconductors for 15 minutes and 120
minutes. The photoconductor and the brush roller rotated at a
linear velocity of 125 mm/sec and 146 mm/sec, respectively. After
applying the protective agent, samples of the photoconductors (2-1)
and (2-2) were analyzed by FT-IR Avatar370 (manufactured by Thermo
Electron Corporation, Thunder Dome) under a condition of one time
reflection, ATR prism of Ge, incident angle of 45.degree. for IR
spectrum analysis to obtain the IR spectrum C (see FIG. 8). As
similar to Example 3-1, the Sb2/Sa2 was computed to obtain
Sb/Sa=8.0 at the 15-minute application time, and Sb2/Sa2=18.6 at
the 120-minute application time.
Agent Bar No. 32
[0391] FT115 (synthesize wax manufactured by Nippon Seiro Co.,Ltd.)
of 55 weight part and trisorbitan stearate (HLB: 1.5) of 25 weight
part, and normal paraffin (average molecular weight 640) of 20
weight part were placed in a glass vessel having a cap, and were
agitated and melted at a temperature of 180 degrees Celcius using a
hot stirrer. Then, the melted protective agent was poured in an
internal space of an aluminum metal mold, having a size of 12
mm.times.8 mm.times.350 mm, heated to 115 degrees Celcius in
advance. After cooling to 90 degrees Celcius on a wooden table, the
aluminum metal mold was cooled to 40 degrees Celcius on an aluminum
table. Then, the solidified product was removed from the mold, and
cooled to an ambient temperature while placing a weight on the
product for preventing a warping. After that, an agent bar No. 12
having a size of 7 mm.times.8 mm.times.310 mm was prepared by
cutting some portion of the product. The protective agent bar No.
32 was attached with a double face tape and fixed to a metal
supporter.
COMPARATIVE EXAMPLE 3-1
Protective Layer Setting Unit (33)
[0392] The photoconductor drums (3-1) and (3-2), a brush roller No.
1 (fiber having a thickness of 10 denier, fiber density of 30,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 31
was pressed against the brush with a spring force of 2 N to apply a
protective agent to the photoconductors for 15 minutes and 120
minutes. The photoconductor and the brush roller rotated at a
linear velocity of 125 mm/sec and 146 mm/sec, respectively. After
applying the protective agent, samples of the photoconductors (3-1)
and (3-2) were analyzed by FT-IR Avatar370 (manufactured by Thermo
Electron Corporation, Thunder Dome) under a condition of one time
reflection, ATR prism of Ge, incident angle of 45.degree. for IR
spectrum analysis to obtain the IR spectrum C (see FIG. 8). As
similar to Example 3-1, the Sb2/Sa2 was computed to obtain
Sb/Sa=6.3 at the 15-minute application time, and Sb2/Sa2=8.1 at the
120-minute application time.
COMPARATIVE EXAMPLE 3-2
Protective Layer Setting Unit (34)
[0393] The photoconductor drums (4-1) and (4-2), a brush roller No.
3 (fiber having a thickness of 20 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The agent bar No. 32
was pressed against the brush with a spring force of 6 N to apply a
protective agent to the photoconductors for 15 minutes and 120
minutes. The photoconductor and the brush roller rotated at a
linear velocity of 125 mm/sec and 146 mm/sec, respectively. After
applying the protective agent, samples of the photoconductors (4-1)
and (4-2) were analyzed by FT-IR Avatar370 (manufactured by Thermo
Electron Corporation, Thunder Dome) under a condition of one time
reflection, ATR prism of Ge, incident angle of 45.degree. for IR
spectrum analysis to obtain the IR spectrum C (see FIG. 8). As
similar to Example 3-1, the Sb2/Sa2 was computed to obtain
Sb/Sa=13.2 at the 15-minute application time, and Sb2/Sa2=38.9 at
the 120-minute application time.
COMPARATIVE EXAMPLE 3-3
Protective Layer Setting Unit (35)
[0394] The photoconductor drums (5-1) and (5-2), a brush roller No.
3 (fiber having a thickness of 20 denier, fiber density of 50,000
fibers per square inch), and a urethane blade were assembled in a
protective layer setting unit (see FIG. 7). The protective agent
bar No. 32 was pressed against the brush with a spring force of 3 N
to apply a protective agent to the photoconductors for 15 minutes
and 120 minutes. The photoconductor drum and the brush roller
rotated at a linear velocity of 125 mm/sec and 146 mm/sec,
respectively. After applying the protective agent, samples of the
photoconductors (5-1) and (5-2) were analyzed by FT-IR Avatar370
(manufactured by Thermo Electron Corporation, Thunder Dome) under a
condition of one time reflection, ATR prism of Ge, incident angle
of 45.degree. for IR spectrum analysis to obtain the IR spectrum C
(see FIG. 8). As similar to Example 3-1, the Sb2/Sa2 was computed
to obtain Sb/Sa=9.4 at the 15-minute application time, and
Sb2/Sa2=25.5 at the 120-minute application time.
[Evaluation of Image Quality]
[0395] When evaluating performance of an image forming apparatus,
IPSIO CX400, a tandem type color image forming apparatus produced
by Ricoh Company, Ltd was used. As for a black process cartridge
(1), a protective layer setting unit having a similar configuration
of the protective layer setting unit (31), used in Example 3-1, was
assembled, wherein the protective layer setting unit includes a
protective agent bar, a brush, and a biasing spring. As for a cyan
process cartridge (1), a protective layer setting unit having a
similar configuration of the protective layer setting unit (33),
used in Comparative Example 3-1, was assembled. As for a magenta
process cartridge (1), a protective layer setting unit having a
similar configuration of the protective layer setting unit (34),
used in Comparative Example 3-2, was assembled. The process
cartridges were installed in IPSIO CX400. A charge roller was
disposed above the photoconductor drum, the photoconductor drum
rotated at a linear velocity of 125 mm/sec, a superimposed voltage
having a direct-current voltage of -600 V and an
alternating-current voltage having a frequency 1450 Hz and an
amplitude of 1100 V was applied between the photoconductor drum and
the charge roller. Each of the process cartridges was installed
with a new photoconductor, which is similar to photoconductors used
in Examples 3-1 to 3-2 and Comparative Examples 3-1 and 3-3.
[0396] When the black, cyan, and magenta process cartridges were
operated to produce one-by-one halftone image of A4 size shown in
FIG. 12 for five sheets to evaluate image quality, it was evaluated
that the black, cyan, and magenta process cartridges produced
higher quality image, as indicated by a circle in FIG. 26. Further,
the black, cyan, and magenta process cartridges were operated to
produce one-by-one halftone image of A4 size shown in FIG. 12 for
50,000 sheets to evaluate image quality, in which five sheets were
printed as one set until 50,000 sheets were printed. In this case,
the black process cartridge produced higher quality image (as
indicated by a circle in FIG. 26), but the cyan process cartridge
produced images having a white streak and the magenta process
cartridge produced images having a black streak, which are not
preferable image quality (as indicated by a cross in FIG. 26).
[0397] Further, another evaluation of image quality was similarly
conducted using the protective layer setting units used in Example
3-2 and Comparative Example 3-3 and process cartridges having such
protective layer setting units. When evaluating performance of an
image forming apparatus, IPSIO CX400, a tandem type color image
forming apparatus produced by Ricoh Company, Ltd was used. As for a
black process cartridge (2), a protective layer setting unit having
a similar configuration of the protective layer setting unit (32),
used in Example 3-2, was assembled, wherein the protective layer
setting unit includes a protective agent bar, a brush, and a
biasing spring. As for a cyan process cartridge (2), a protective
layer setting unit having a similar configuration of the protective
layer setting unit (35), used in Comparative Example 3-3, was
assembled. The process cartridges were installed in IPSIO CX400. A
charge roller was disposed above the photoconductor drum, the
photoconductor drum rotated at a linear velocity of 125 mm/sec, a
superimposed voltage having a direct-current voltage of -600 V and
an alternating-current voltage having a frequency 1450 Hz and an
amplitude of 1100 V was applied between the photoconductor drum and
the charge roller. Each of the process cartridges was installed
with a new photoconductor, which is similar to photoconductors used
in Examples 3-1 to 3-2 and Comparative Examples 3-1 and 3-3.
[0398] When the black, and cyan process cartridges were operated to
produce one-by-one halftone image of A4 size shown in FIG. 12 for
five sheets to evaluate image quality, it was evaluated that the
black and cyan process cartridges produced higher quality image, as
indicated by a circle in FIG. 26.
[0399] Further, the black and cyan process cartridges were operated
to produce one-by-one halftone image of A4 size shown in FIG. 12
for 50,000 sheets to evaluate image quality, in which five sheets
were printed as one set until 50,000 sheets were printed.
[0400] In this case, the black process cartridge produced higher
quality image (as indicated by a circle in FIG. 26), but the cyan
process cartridge produced images having a white streak, which is
not preferable image quality (as indicated by a cross in FIG.
26).
[0401] FIGS. 24 to 27 show conditions for protective agent bars,
protective layer setting units, ATR analysis, and results of ATR
analysis and image evaluation for Examples 3 and Comparative
Examples 3.
[0402] As above described in exemplary embodiments, an amount of
protective agent applied on an image carrying member, such as
photoconductor, can be reliably evaluated with the aforementioned
method even if the protective agent does not include metal
component, wherein such protective agent may include paraffin, for
example. With such evaluation method, an application amount of the
protective agent can be reliably evaluated, by which a protective
layer setting unit that can reduce an occurrence of abnormal image
can be provided. Further, such protective layer setting unit can be
preferably employed for a process cartridge and an image forming
apparatus.
[0403] Numerous additional modifications and variations are
possible in light of the above teachings. It is therefore to be
understood that within the scope of the appended claims, the
disclosure of the present invention may be practiced otherwise than
as specifically described herein. For example, elements and/or
features of different examples and illustrative embodiments may be
combined each other and/or substituted for each other within the
scope of this disclosure and appended claims.
* * * * *